Empirical Study of Foundry Efficiency Improvement Based on Data-Driven Techniques

In this paper, a data-driven approach was applied to improve a furnace zone of a foundry in Taiwan. Improvements are based on the historical production records, order-scheduling, and labor-scheduling data. To resolve the bottleneck provided by the company, historical data were analyzed, and the existence of large variance in the process was found. Statistical analysis was performed to identify the primal factors causing the variance, and suggestions were made and implemented to the production line. As a result, daily production increased steadily to more than 30 pots of molten metal, while the original production was 20–30 pots of molten metal and are not controllable. Such significant improvement was mainly made by standardizing the input and reducing the variance of processes. The average cycle time of each pot of molten metal was reduced from 219 min to 135 min. Our suggested improvements also reduced the foundry’s electricity consumption cost by almost $240,000NT per month. In summary, data analysis can help traditional industries in identifying the main factors causing the bottleneck.

ANALISIS PENJADWALAN TENAGA KERJA DENGAN MENGGUNAKAN METODE TIBREWALA, PHILIPPE DAN BROWNE PADA PT. JAPFA COMFEED INDONESIA TBK. UNIT MAKASSAR

Labor scheduling is the allocation of human resources to the work stations according to the needs. To increase productivity the company must schedule the labor optimally. PT. Japfa Comfeed Indonesia Tbk. Makassar Unit is one of company that produces the animal feed with a capacity of 4 tons in a day that located on Jalan Ir. Sutami KM 17 PO BOX Makassar. In workers allocating, the company implements labor scheduling with 3 work shifts and 1 day off in 1 week in the production section. Human resources are very important to notice. Therefore, to increase the productivity of the company so it's need for additional day off for each part of the labor production. To accommodate 3 work shifts in a day and 2 days off in 1 week, this research used a modified of tibrewala, philippe and browne algorithm method. Modification of this algorithm changes and adds from 3 steps to 5 steps and changes the tabular table format for scheduling workers for three shifts. Labor Scheduling with 5 working days and 2 days off needs of 20 people of labor in the hand add process, 36 people in the bagging process, 7 people in the panel process and 7 people in the press process. The excess of labor that occurred was 9 man days (equivalent to 5.6 people) in the hand add process, 36 man days (equivalent to 7.2 people in the bagging process, 17 man-days (equivalent to 3.4 people) on the panel process and 17 man-days (equivalent to 3.4 people) in the press process. The excess of the labor can be utilized when the labor is not going to work because of illness, permission or leave. This scheduling is expected to be able to keep the health and safety of the labor so that it can be optimal to work to increase the productivity of the company.

PERENCANAAN PENJADWALAN TENAGA KERJA PADA UKM SONGKOK IKAT KEPALA

Songkok Ikat Kepala was one of UKM which produce songkok in Gresik. This UKM Songkok Ikat Kepala was produced by strategy “make to order” and there was no guideline for period production. Problems that occurred were known asdelayed production process at the process of sewing. The aim of this study was (1) to analyze the planning of labor scheduling and (2) to determine the standard of estimation of item production process. The data were analyzed by using period study and gantt diagram techniques. The results of the study showed that there were 2 standards of estimation, those are fast and low standards. Fast standard needed the work estimation in 444 seconds. However, low standard needed the work estimation in 536 seconds. Therefore, this study was expected to be guidance to arrange the schedule by using gantt diagram.