Calculation of Labor Amount with Theory of Constraints and Line Balancing Method in PT. XYZ Fish Crackers Factory

Abstract

The right amount of labor on work station is important to avoid uneven workload, that might reduce efficiency on production line, and cause bottleneck. Therefore, this research focus at searching the optimal amount of labor using line balancing and bottleneck that occurs on XYZ Fish Crackers Factory. Theory of constraints method is used to identify bottleneck, and line balancing method that will be used is Kilbridge-Wester, Moodie Young, Helgeson-Birnie, and J-Wagon. Fish cracker drying is the process that encounter bottleneck. The beginning line efficiency is 50.09%, with Kilbridge-Wester, Helgeson Birnie, and J- Wagon method, the line efficiency is 89.22%, and with Moodie Young method, the line efficieny is 89.45%. Therefore, Moodie Young method is the best method to apply, because it has the best result, with 89.45% line efficiency, 10.55% balance delay, 13.96% smoothness index, 20.3 minutes of idle time, 5 work station, and amount of labor needed is 10 person.