The Problem of Production Path Balance

Oct 13, 2025 by vinooalluri.com 141 views

Introduction

In today's competitive manufacturing industry, companies are constantly seeking ways to improve their production efficiency and output. One of the key challenges faced by manufacturers is maintaining a balance between production paths, which can lead to bottlenecks and delays in the production process. PT. Cahaya Kawi Ultra Polyintraco, a company that produces spring bed mattresses, is no exception. With four different types of products and a mass production and order system, the company faces significant challenges in maintaining an efficient balance of production paths.

The Problem of Production Path Balance

The production process at PT. Cahaya Kawi Ultra Polyintraco involves several work stations, including the wire assembly station, assembly station per round, and gluing station. However, the wire assembly station has been identified as a bottleneck, with an average capacity of 15.7 minutes per unit and only one unit of equipment used. This bottleneck has a significant impact on the smooth production at the next work stations, resulting in delays and inefficiencies in the production process.

The Need for a Production Path Balance System

To overcome the challenges of production path balance, this study aims to design a production path balance system using simulation techniques. The simulation software used is Promodel, a powerful tool for modeling and analyzing complex systems. The initial analysis of the path balance shows that there is a delay balance of 34.22% and the path efficiency is only 65.78%. This indicates that the production path in the factory is still not optimal, with an average mattress production in one week around 120 units.

Design of the Simulation Model

The simulation model was designed with a 95% confidence interval and simulation analysis that uses terminating simulation. The model was validated by comparing the results with the actual production data, and it was found that the simulation model was valid in representing a real system on the production floor of PT. Cahaya Kawi Ultra Polyintraco. The average mattress production in the simulation model was 119 units, which is close to the actual production data.

Alternative Scenarios

To improve the performance of the system, three alternative scenarios were generated using the simulation model. The results of the alternative model generation show different performance parameters:

Alternative Model 1: The average time in the system is 262.51 minutes and the average production of 131 units.
Alternative Model 2: The average time in the system is 287.85 minutes and an average production of 122 units.
Alternative Model 3: Average time in the system 272.04 minutes and an average production of 122 units.

Conclusion

The results of this study demonstrate the importance of simulation techniques in designing a production path balance system. By analyzing the production process and identifying bottlenecks, companies can take steps to improve their production efficiency and output. The implementation of the proposed model can be expected to reduce bottlenecks and increase overall productivity in PT. Cahaya Kawi Ultra Polyintraco. This study contributes important to companies in improving the quality and quantity of production results, as well as assisting in better decision making in production management.

Recommendations

Based on the results of this study, the following recommendations are made:

Implement the proposed model: The proposed model can be implemented in PT. Cahaya Kawi Ultra Polyintraco to reduce bottlenecks and increase overall productivity.
Continuously monitor and analyze the production process: Continuous monitoring and analysis of the production process can help identify areas for improvement and optimize the production path balance system.
Train production staff: Training production staff on the use of simulation techniques and the proposed model can help them understand the importance of production path balance and make informed decisions.

Limitations of the Study

This study has several limitations, including:

Limited data: The study was based on limited data from PT. Cahaya Kawi Ultra Polyintraco, which may not be representative of other companies.
Simplification of the production process: The production process was simplified for the purpose of this study, which may not reflect the actual complexity of the production process.
Assumptions made: Several assumptions were made in the study, including the assumption that the production path balance system is the primary cause of bottlenecks and delays in the production process.

Future Research Directions

Future research directions include:

Validation of the proposed model: The proposed model should be validated in other companies to ensure its generalizability.
Extension of the study: The study should be extended to include other factors that may affect production path balance, such as equipment maintenance and supply chain management.
Development of a more complex simulation model: A more complex simulation model should be developed to reflect the actual complexity of the production process.

Conclusion

In conclusion, this study demonstrates the importance of simulation techniques in designing a production path balance system. By analyzing the production process and identifying bottlenecks, companies can take steps to improve their production efficiency and output. The implementation of the proposed model can be expected to reduce bottlenecks and increase overall productivity in PT. Cahaya Kawi Ultra Polyintraco. This study contributes important to companies in improving the quality and quantity of production results, as well as assisting in better decision making in production management.

Introduction

In our previous article, we discussed the design of a production path balance system at PT. Cahaya Kawi Ultra Polyintraco using simulation techniques. In this article, we will answer some of the frequently asked questions (FAQs) related to the study.

Q: What is the main objective of the study?

A: The main objective of the study is to design a production path balance system at PT. Cahaya Kawi Ultra Polyintraco using simulation techniques to improve production efficiency and output.

Q: What is the significance of the study?

A: The study is significant because it demonstrates the importance of simulation techniques in designing a production path balance system. By analyzing the production process and identifying bottlenecks, companies can take steps to improve their production efficiency and output.

Q: What are the limitations of the study?

A: The study has several limitations, including limited data, simplification of the production process, and assumptions made.

Q: How can the proposed model be implemented in PT. Cahaya Kawi Ultra Polyintraco?

A: The proposed model can be implemented in PT. Cahaya Kawi Ultra Polyintraco by training production staff on the use of simulation techniques and the proposed model, and by continuously monitoring and analyzing the production process.

Q: What are the benefits of implementing the proposed model?

A: The benefits of implementing the proposed model include reduced bottlenecks and increased overall productivity, improved quality and quantity of production results, and better decision making in production management.

Q: How can the study be extended?

A: The study can be extended by validating the proposed model in other companies, extending the study to include other factors that may affect production path balance, and developing a more complex simulation model.

Q: What are the future research directions?

A: The future research directions include validation of the proposed model, extension of the study, and development of a more complex simulation model.

Q: What are the recommendations of the study?

A: The recommendations of the study include implementing the proposed model, continuously monitoring and analyzing the production process, and training production staff on the use of simulation techniques and the proposed model.

Q: What are the implications of the study?

A: The implications of the study are that simulation techniques can be used to design a production path balance system, and that by analyzing the production process and identifying bottlenecks, companies can take steps to improve their production efficiency and output.

Conclusion

In conclusion, the Q&A article provides answers to some of the frequently asked questions related to the study on the design of a production path balance system at PT. Cahaya Kawi Ultra Polyintraco using simulation techniques. The study demonstrates the importance of simulation techniques in designing a production path balance system, and provides recommendations for implementing the proposed model and extending the study.

Recommendations for Future Research

Based on the study, the following recommendations are made for future research:

Validation of the proposed model: The proposed model should be validated in other companies to ensure its generalizability.
Extension of the study: The study should be extended to include other factors that may affect production path balance, such as equipment maintenance and supply chain management.
Development of a more complex simulation model: A more complex simulation model should be developed to reflect the actual complexity of the production process.