DAFTAR ISI LEMBAR PENGESAHAN ............................................................................................................. ii ABSTRAK ...................................................................................................................................... iv KATA PENGANTAR ..................................................................................................................... v DAFTAR ISI.................................................................................................................................. vii DAFTAR TABEL ............................................................................................................................ x DAFTAR GAMBAR ..................................................................................................................... xii BAB I PENDAHULUAN 1.1 Latar Belakang Masalah ..................................................................................................... I-1 1.2 Perumusan Masalah ............................................................................................................ I-2 1.3 Tujuan Penelitian ................................................................................................................ I-3 1.4 Pembatasan Masalah dan Asumsi ....................................................................................... I-3 1.5 Manfaat Penelitian .............................................................................................................. I-3 1.6 Sistematika Penulisan ......................................................................................................... I-3 BAB II LANDASAN TEORI 2.1 Layout ................................................................................................................................ II-1 2.2 Line Balancing ................................................................................................................... II-2 2.3 Istilah-istilah Dalam Line Balancing ................................................................................. II-3 2.4 Metode-Metode Line Balancing ....................................................................................... III-7 2.4.1 Metode Kilbridge-Wester Heuristic ........................................................................... III-7 2.4.2 Metode Helgeson-Birnie (Positional-Weight Technique) ....................................... III-11 2.4.3 Metode Moodie-Young............................................................................................. III-13 2.4.4 Metode Rank and Assign Heuristic (RA) ................................................................. III-16 2.4.5 Metode Mathematical Programming Formulation ................................................. III-18 2.4.6 The Single-Row Machine Layout Problem by Genetic Algorithm ........................... III-24 vi
BAB III METODOLOGI PENELITIAN 3.1 Tahapan Penelitian ............................................................................................................ III-1 3.2 Uraian Tahapan Pemecahan Masalah ............................................................................... III-2 3.2.1 Penelitian Tugas Akhir .............................................................................................. III-2 3.2.2 Studi Literatur ............................................................................................................ III-2 3.2.3 Identifikasi dan Perumusan Masalah ......................................................................... III-2 3.2.4 Penetapan Tujuan ....................................................................................................... III-2 3.2.5 Pengumpulan Data ..................................................................................................... III-2 3.2.6 Pengolahan Data ........................................................................................................ III-3 3.2.7 Analisis ...................................................................................................................... III-7 3.2.8 Kesimpulan dan Saran ............................................................................................... III-7 BAB IV PENGOLAHAN DAN PENGUMPULAN DATA 4.1 Pengumpulan Data ............................................................................................................IV-1 4.1.1 Sejarah Perusahaan ....................................................................................................IV-1 4.1.2 Aktivitas Produksi di PT Multi Garmen Jaya ............................................................IV-1 4.1.3 Data Waktu Proses Setiap Elemen Kerja pada Line Jahit Perusahaan ......................IV-3 4.1.4 Precedence Diagram Elemen Kerja pada Line Jahit Perusahaan ..............................IV-4 4.1.5 Layout Line Jahit Perusahaan.....................................................................................IV-4 4.1.6 Precedence Matriks Elemen Kerja pada Line Jahit Perusahaan ................................IV-5 4.1.7 Assembling Proses Chart (APC) Elemen Kerja pada Line Jahit Perusahaan ............IV-6 4.2 Pengolahan Data ...............................................................................................................IV-7 4.2.1 Line Balancing Elemen Kerja pada Line Jahit Perusahaan Saat Ini ..........................IV-7 4.2.2 Line Balancing Elemen Kerja Menggunakan Metode Helgeson-Birnie ...................IV-9 4.2.3 Line Balancing Elemen Kerja Menggunakan Metode Kilbridge-Wester ................IV-12 4.2.4 Line Balancing Elemen Kerja Menggunakan Metode Moodie-Young ....................IV-15 vii
4.2.5 Line Balancing Elemen Kerja Menggunakan Metode Rank and Assign Heuristic .IV-17 4.2.6 Line Balancing Elemen Kerja Menggunakan Mathematical Programming Formulation dengan Software WinQSB ............................................................................IV-19 4.2.7 Line Balancing Elemen Kerja Menggunakan The Single-Row Machine Layout Problem by Genetic Algorithm .........................................................................................IV-28 BAB V ANALISIS 5.1 Analisis Efisiensi Metode-metode Line Balancing............................................................ V-1 5.2 Analisis Layout Line Balancing Masing-masing Metode.................................................. V-2 BAB VI KESIMPULAN DAN SARAN 6.1 Kesimpulan .......................................................................................................................VI-1 6.2 Saran .................................................................................................................................VI-1 DAFTAR PUSTAKA ................................................................................................................... xiv
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DAFTAR TABEL
Tabel 2.1 Waktu Proses Kasus 1.................................................................................................. II-8 Tabel 2.2 Penugasan Workstation ................................................................................................ II-9 Tabel 2.3 Elemen Pendahulu Untuk Setiap Elemen Kerja ........................................................ II-10 Tabel 2.4 Elemen-elemen Penugasan Untuk Workstations (CT=10) ........................................ II-10 Tabel 2.5 Elemen-elemen Penugasan Untuk Workstations (CT=9) .......................................... II-11 Tabel 2.6 Urutan Bobot Operasi Elemen Kasus 1 ..................................................................... II-12 Tabel 2.7 Urutan Bobot Operasi Elemen Berdasarkan Positional Weight ................................ II-12 Tabel 2.8 Elemen-elemen Penugasan Untuk Workstations (CT=10) ........................................ II-13 Tabel 2.9 Matrik P dan F Kasus 1.............................................................................................. II-15 Tabel 2.10 Penugasan Pada Fase 1 ............................................................................................ II-16 Tabel 2.11 Urutan Bobot Operasi Elemen Berdasarkan Score Metode RA .............................. II-17 Tabel 2.12 Elemen-elemen Penugasan Untuk Workstations (CT=10) ...................................... II-17 Tabel 2.13 Element Time dan Precedence Requirement ........................................................... II-20 Tabel 2.14 Penugasan Elemen Ke Workstations, CT=20 .......................................................... II-23 Tabel 2.15 Penugasan Elemen Ke Workstations, CT=15 .......................................................... II-24 Tabel 2.16 Tugas Setiap Stasiun Kerja Dalam Memproduksi Kemeja Pria .............................. II-33 Tabel 2.17 Efektifitas Penilaian Dari Perbaikan Layout Mesin Berbentuk U ........................... II-34 Tabel 4.1 Jenis Mesin dan Waktu Proses Tiap Elemen Kerja ....................................................IV-3 Tabel 4.2 Precendence Matriks Elemen Kerja ...........................................................................IV-5 Tabel 4.3 Total Waktu Proses Setiap Elemen Kerja ...................................................................IV-7 Tabel 4.4 Persentase Line Balancing pada Line Jahit Perusahaan..............................................IV-8 Tabel 4.5 Urutan Total Waktu Proses Setiap Elemen Kerja dari yang Terbesar ......................IV-10 Tabel 4.6 Persentase Line Balancing pada Line Jahit Berdasarkan Metode Helgeson-Birnie .IV-11 Tabel 4.7 Persentase Line Balancing pada Line Jahit Berdasarkan Metode Kilbridge-Wester IV-14 Tabel 4.8 Matriks Proses Elemen Kerja ...................................................................................IV-15 Tabel 4.9 Persentase Line Balancing pada Line Jahit Berdasarkan Metode Moodie-Young ....IV-16 Tabel 4.10 Urutan Total Waktu Proses Setiap Elemen Kerja dari yang Terbesar ....................IV-17 Tabel 4.11 Persentase Line Balancing pada Line Jahit Berdasarkan Metode Rank and Assign Heuristic....................................................................................................................................IV-18 ix
Tabel 4.12 Waktu Elemen Kerja dan Precedence Requirement ...............................................IV-20 Tabel 4.13 Persentase Line Balancing pada Line Jahit Berdasarkan Software WinQSB ..........IV-27 Tabel 4.14 Persentase Line Balancing pada Line Jahit .............................................................IV-29 Tabel 5.1 Perbandingan Metode-metode Line Balancing............................................................ V-1
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DAFTAR GAMBAR
Gambar 2.1 Precendence Diagram Kasus 1 ................................................................................ II-8 Gambar 2.2 Precendence Diagram Kasus 2 .............................................................................. II-19 Gambar 2.3 Bentuk Layout Mesin ............................................................................................. II-26 Gambar 2.4 Precedence Diagram.............................................................................................. II-27 Gambar 2.5 Precendence Relationship of Modular Order ........................................................ II-28 Gambar 2.6 Chromosomes Of The Hierarchical Order-Based Genetic Algorithm................... II-28 Gambar 2.7 Crossover Of The Hierarchical Order-Based Genetic Algorithm ......................... II-30 Gambar 2.8 Scramble Sub-list Mutation .................................................................................... II-30 Gambar 2.9 Precendence Diagram Produksi Kemeja Pria ....................................................... II-32 Gambar 2.10 Chromosomes Hierarchical Order-Based Genetic Algorithm Produksi Kemeja Pria……………………………………………………...……………………………………..II-32 Gambar 2.11 Perbaikan Layout Mesin Berbentuk U ................................................................. II-32 Gambar 2.12 Nilai Kebugaran dan Nilai Jarak Perpindahan Tiap Generasi ............................. II-33 Gambar 3.1 Flow Chart Penelitian ............................................................................................. III-1 Gambar 3.2 Langkah-langkah Pengolahan Data Menggunakan Genetic Algorithm .................. III-6 Gambar 4.1 Precendence Diagram Elemen Kerja ......................................................................IV-4 Gambar 4.2 Layout Line Jahit Perusahaan Saat Ini ....................................................................IV-4 Gambar 4.3 APC Elemen Kerja pada Line Jahit Perusahaan .....................................................IV-6 Gambar 4.4 Hasil Layout Line Jahit Perusahaan Menggunakan Metode Helgeson-Birnie......IV-12 Gambar 4.5 Pengelompokan Level Elemen Kerja Berdasarkan Aliran Proses ........................IV-13 Gambar 4.6 Hasil Layout Line Jahit Perusahaan Menggunakan Metode Kilbridge-Wester ....IV-15 Gambar 4.7 Hasil Layout Line Jahit Perusahaan Menggunakan Metode Moodie-Young ........IV-17 Gambar 4.8 Hasil Layout Line Jahit Perusahaan Menggunakan ..............................................IV-19 Gambar 4.9 Hasil Pengolahan Data Menggunakan Software WinQSB ....................................IV-26 Gambar 4.10 Hasil Layout Line Jahit Perusahaan ....................................................................IV-27 Gambar 4.11 Hasil Pengolahan Data ........................................................................................IV-28 Gambar 4.12 Hasil Layout Line Jahit Perusahaan ....................................................................IV-29 Gambar 5.1a Layout Perusahaan Saat Ini .................................................................................... V-3 Gambar 5.1b Layout Metode Helgeson-Birnie ............................................................................ V-3 xi
Gambar 5.1c Layout Metode Kilbridge-Wester ........................................................................... V-3 Gambar 5.1d Layout Metode Moodie-Young............................................................................... V-4 Gambar 5.1e Layout Metode Rank and Assign Heuristic ............................................................ V-4 Gambar 5.1f Layout Mathematical Programming Formulation ................................................. V-4 Gambar 5.1g Layout The Single-Row Machine Layout Problem by Genetic Algorithm ............. V-5
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DAFTAR PUSTAKA •
Heragu, Sunderesh S, Facilities Design Third Edition, CRC Press, New York, 2008.
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Elsayed, Elsayed. A, Analysis and Control of Produkciton Systems, Prentice Hall, New Jersey, 1994.
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Gavin Amborse dan Paul Harris, Layout, London, 2005.
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Fogarty, Donald.W and Blackstone, John. H, Production and Inventory Management Secend Edition, South-Western, Cinnati City, 1991.
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Biegle, John. E, Production Control A Quantitative Approach Secend Edition, Prentice Hall, 1990.
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Tzu Lin, Miao, (2008), “The Single Row Machine Layout Problem In Apparel Manufacturing by Hierarchical Order-Based Genetic Algorithm”, International Journal of Clothing Science and Technology, Vol. 21, pp. 31-43.
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