The Lean Manufacturing Design for Improving Production Scheduling Using Product WheelMethod in Chemical Manufacturing Company, Indonesia

Abstract

The current production scheduling policy at PT XYZ raises several problems, including the long production lead time for each product, unbalanced inventory between products, and the unavailability of goods requested by customers. Therefore, this research will focus on designing production scheduling improvements at PT XYZ in order to be able to overcome current problems. The product wheel method was chosen to be a proposal to improve production scheduling at PT. XYZ Based on the calculation of Economic Production Quantity (EPQ), the product wheel's production schedule is made into three cycles in which every cycle runs for two days. Cycle 1 produces Tonsil C 1000 by 200 tons, Tonsil B 1000 150 tons, Tonsil A 1000, and Tonsil B Cylo as much as 50 tons each. Cycle 2 produces Tonsil C 1000 for 200 tons, Tonsil B 1000 150 tons, Tonsil A 1000 100 tons, and Tonsil B Cylo for 50 tons. Cycle 3 produces 200 tons of Tonsil C 1000, Tonsil B 1000, Tonsil A 1000, Tonsil B Cylo, Tonsil C 25, and Tonsil B 25, each with 50 tons. Because Tonsil C 25 and Tonsil B 25 are MTO products, they do not always have to be produced when cycle three spins. By scheduling production using the product wheel, we get a more dynamic production schedule than the production scheduling at PT. The previous XYZ was due to product wheel scheduling, the quantity produced, and the production sequence was made based on customer demand so that it was expected that production could run effectively and efficiently.