PRODUCTION LINE AND LAYOUT IMPROVEMENT AT PT. AGUNG PERSADA SLEMAN

PT. Agung Persada Sleman is manufacturing company mainly produces spring beds and regular beds. Currently, spring bed production team still can not meet the production target which is 80 units per day, while the average output is only 43 until 65 units per day. A preliminary observation found that the low productivity is caused by inefficient production line, inefficient material handling, and poor layout design. This research is carried out in order to balance the production line, allocate the worker, and shorten the distance between each work center in order to reach the production target. The line improvement is carried out by adopting rank position weight (RPW) analysis with two different cycle time for priority products. The first cycle time is using the longest time among the workstations, while the second cycle time is using the desired takt time. By re-allocating the workers and adjusting the number of work tables in each work center, the line efficiency increases about 36.10% by using the desired cycle time. The line efficiency also increases about 50.79% compared to the current condition of the company by using current company cycle time. The layout improvement analysis is carried out by adopting systematic layout planning (SLP) approach with the help of Blocplan software. By re-designing the new suggested layout, this research can reduce the distance about 42% (3135.35 meters) per day that reduces the time taken to do the material handling