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"[Penelitian ini bertujuan untuk membantu PT Metal Diameter menyusun rencana produksi yang tepat dengan menerapkan product mix algorithm dan drum buffer rope berdasarkan prinsip five focusing steps dari theory of constraints dalamrangka memaksimalkan throughput. Metode penelitian yang digunakan dalam penelitian ini adalah metode deskriptif dengan data primer. Perencanaan produksi berdasarkan metode tersebut dimulai dengan mengidentifikasi sumber daya kendala. Sumber daya kendala yang telah teridentifikasi akan dieksploitasi melalui aplikasi product mix algorithm dan buffer, setelah itu sumber daya nonkendala akan disubordinasi ke sumber daya kendala dengan membuat jadwal produksi optimal melalui aplikasi rope. Selanjutnya, penelitian ini menyarankan PT Metal Diameter untuk menerapkan metode tersebut dalam penyusunan rencana produksi karena lebih sesuai dengan keadaan lini produksi yang sebenarnya, yang mana terdapat sumber daya yang mengalami keterbatasan kapasitas dan terdapat kemungkinan gangguan internal (breakdown).

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This research aims to help PT Metal Diameter in preparing proper production plan by applying product mix algorithm and drum buffer rope based on five focusing steps principle from theory of constraints in order to maximize throughput. The method used in this research is descriptive method with the primary data. Production planning based on that method starts with identifying resource constraints. Resource constraints that have been identified will be exploited through product mix algorithm and buffer application, while non-resource constraints will be subordinated to the resource constraints by creating optimal production schedule through the rope application. Furthermore, this study suggests PT Metal Diameter to apply this method in preparing proper production plans because it will be more in line with the actual state of the production line, which have resources with limited capacity and the possibility of internal disturbances (breakdown). This research aims to help PT Metal Diameter in preparing proper production plan by applying product mix algorithm and drum buffer rope based on five focusing steps principle from theory of constraints in order to maximize throughput. The method used in this research is descriptive method with the primary data. Production planning based on that method starts with identifying resource constraints. Resource constraints that have been identified will be exploited through product mix algorithm and buffer application, while non-resource constraints will be subordinated to the resource constraints by creating optimal

production schedule through the rope application. Furthermore, this study suggests PT Metal Diameter to apply this method in preparing proper production plans because it will be more in line with the actual state of the production line, which have resources with limited capacity and the possibility of internal disturbances (breakdown). This research aims to help PT Metal Diameter in preparing proper production plan by applying product mix algorithm and drum buffer rope based on five focusing steps principle from theory of constraints in order to maximize throughput. The method used in this research is descriptive method with the primary data. Production planning based on that method starts with identifying resource constraints. Resource constraints that have been identified will be exploited through product mix algorithm and buffer application, while non-resource constraints will be subordinated to the resource constraints by creating optimal

production schedule through the rope application. Furthermore, this study suggests PT Metal Diameter to apply this method in preparing proper production plans because it will be more in line with the actual state of the production line, which have resources with limited capacity and the possibility of internal disturbances (breakdown). This research aims to help PT Metal Diameter in preparing proper production plan by applying product mix algorithm and drum buffer rope based on five focusing steps principle from theory of constraints in order to maximize throughput. The method used in this research is descriptive method with the primary data.

Production planning based on that method starts with identifying resource constraints. Resource constraints that have been identified will be exploited through product mix algorithm and buffer application, while non-resource constraints will be subordinated to the resource constraints by creating optimal

production schedule through the rope application. Furthermore, this study suggests PT Metal Diameter to apply this method in preparing proper production plans because it will be more in line with the actual state of the production line, which have resources with limited capacity and the possibility of internal disturbances (breakdown).;This research aims to help PT Metal Diameter in preparing proper production plan

by applying product mix algorithm and drum buffer rope based on five focusing

steps principle from theory of constraints in order to maximize throughput. The

method used in this research is descriptive method with the primary data.

Production planning based on that method starts with identifying resource

constraints. Resource constraints that have been identified will be exploited

through product mix algorithm and buffer application, while non-resource

constraints will be subordinated to the resource constraints by creating optimal

production schedule through the rope application. Furthermore, this study

suggests PT Metal Diameter to apply this method in preparing proper production

plans because it will be more in line with the actual state of the production line,

which have resources with limited capacity and the possibility of internal

disturbances (breakdown)., This research aims to help PT Metal Diameter in preparing proper production plan

by applying product mix algorithm and drum buffer rope based on five focusing

steps principle from theory of constraints in order to maximize throughput. The

method used in this research is descriptive method with the primary data.

Production planning based on that method starts with identifying resource

constraints. Resource constraints that have been identified will be exploited

through product mix algorithm and buffer application, while non-resource

constraints will be subordinated to the resource constraints by creating optimal

production schedule through the rope application. Furthermore, this study

suggests PT Metal Diameter to apply this method in preparing proper production

plans because it will be more in line with the actual state of the production line,

which have resources with limited capacity and the possibility of internal

disturbances (breakdown).]"

"PT X merupakan seOuah perusahaan perakitan truk.Sistem produksi yang digunakan saat ini adalah sistem push dan make to stock dengan berusaha melakukan penyeimbangan lini pada lini perakitannya. Ternyata PT X belum mampu mencapai target produksi rata-rata bulanan yang diharapkan. Hal ini diidentiflkasi dlsebabkan terutama karena hambatan internal peralatan produksi. Peralatan yang dalam hal ini merupakan pos kerja internal dirancang utllisasinya semaksimal mungkin .Konsep dasar sistem produksi yang digunakan ialah Theory of Constraints (TOC). Dari 5 langkah-langkah implem¢ntasi TOC, maka dihasilkan sebuah jadwal bagi kendala, dan penyediaan besar buffer yang sesuai untuk menjaga utilisasi pos kendala dan koordinasi pelepasan material ke lini. Konsep ini disebut juga sebagai drum-buffer-rope. Sumbangan yang diharapkan ialah pengenalan konsep Theory of Conslrainls sebagai salah satu konsep sistem produksi yang makin berkembang penggunaannya selain konsep sistem produksi yang telah ada yakni JIT (Just In Time) dan MRP (Material Requirements Planning).

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PT X is a truck assl!mbling company Rec.ml production system is push system and make to stock; wilh an effort lQ balance their line of production. U'!fortunate(v. PT X's ,production depmtment seldom achieve !he targetJhai was already written by their marketing defXlriment. The cause is identified to be an intemal constraint in production equipment. An eqmpment which m this case app!!ar to be an intemallVorkstation. is desig ;ed its ma:dmal utilisatioJt The basic concept that underlying the solution is Theory ofConslroints. Based by TOC 'sfirefocusing steps, PT X needs a schedule for the constraint only, preparation of time buffer in front of thll constraint, and a subordination for maten·az supply to the line. This..."

"Perencanaan produksi merupakan aspek penting yang hams diperhatikan oleh sebuah perusahaan rnanufaktun Walaupun demikian, rencana produksi yang disusun oleh perusahaan seringkali tidak beljalan densn nama theory of constraints (TOC) dapat Cligunakan untuk menyusun rencana produksi berdasarkan kendala.Perencanaan produksi dimulai dengan mengidentifikasi kendaia yang dimiliki perusahaan Setelah itu, kendala dieksploitasi dengan cara menentukan produc! mb: yang optimal yang akan memaksimaikan keunlungan. Product mix yang optimal dapat ditentukan dengan menggunakan prograrna linier. Ketepatan hasil yang diperolch dari programa linier tergantung pada keakuratan input data yang meliputi data biaya produk. Inforrnasi biaya produk yang lebih akurat dapat diperoleh dengan nlenggunakan metode activity-based cosring (ABC).Product mix yang optimal ini merupakan input bagi penyusunan jadwal produksi. Jadwal produksi disusun berdasarkan metode drum-buffer-rope (DBR)- Perencanaan produksi dilanjutkan dengan membuat suatu rencana koordinasi unluk mendulcung implementasi jadwai produksi yang telah djbuat. Dengan demikian perencanaan produksi yang dibuat dapat memberikan arahan bagi pelaksanaan kegiatan produksi dengan baik.

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Production planning is important aspect that must be considered by a manufacturing company. However, it's often that the company's production plan doesn't work well. Thus, reducing the company's competitiveness in the globalization era. Production planning should consider restrictive bottlenecks of a company so that production activity that is implemented according to the plan may work well. A concept that is known as theory of constraints (TOC) can be used to make production plan based on bottlenecks.

Production planning starts with identifying bottlenecks of company. Then, bottlenecks are exploited by determining the optimal product mix that maximize company's profit. The optimal product mix can be determined with linear programming. The accuracy of linear programming's result depends on the accuracy of input, including product cost. More accuracy in product cost information can be obtained by applying activity-based costing (ABC) method.

This optimal product mix is input for production scheduling. Production scheduling is made according to drum-buffer-rope (DBR) method. Production planning is continued with a coordination plan to support the implementation of production schedule. Thus, production planning that has been made could give the right direction for production activity implementation."

"ABSTRAKPelaksanaan produksi di PT ?X? sering mengalami kesulitan untuk memenuhi permintaan dari konsumennya dikarenakan kondisi permintaan yang selalu berfluktuatif. Dengan demikian perusahaan perlu membuat suatu srategi proses produksi dalam mengantisipasi permintaan tersebut dengan mempertimbangkan biaya produksi yang paling minimal.Dalam menentukan strategi proses produksi diterapkan metode Chase Strategy, Assigned Workforce Levels dan Level Strategy dengan kriteria minimasi ongkos totalnya. Variabel-variabel ongkosnya meliputi ongkos tenaga kerja langsung, ongkos rekrut, ongkos PH, ongkos jam kerja normal, ongkos lembur, ongkos simpan, ongkos backorder dan ongkos lost sales.Dengan bantuan program Quantitative systems (QS) version 3.0 dipilih metode terbaik dari ketiga metode yang diusulkan. Secara keseluruhan didapat strategi yang terbaik yaitu dengan memakai metode Assigned Workforce Levels yang memberikan ongkos total kumulatif tenaga kerja per tahun sebesar Rp. 9.945.847,- sedangkan ongkos total produksi per tahun untuk Audio part sebesar Rp. 83.723.960,- TV part sebesar Rp. 133.800.216,- Rak Nasional sebesar Rp. 720.194.496,- Rak Sanyo sebesar Rp. 764.004.288,- Rak Mitsubitshi seb.car Rp. 836.290.560,- MDF 2500 sebesar Rp.887.041.472,- dan MDF 3000 sebesar Rp. 1.190.621.440,-

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ABSTRACT

The carrying out of production at PT. 'X' frequently find it difficult to meet the demand of its consumers, because of the demand's condition which is very fluctuate. The company needs a kind of process production strategy to anticipate the demand by considering the minimum production cost.

In determining the process production strategy, method of Chase strategy, Assigned Workforce levels and Level strategy are implemented with the criteria of minimized total cost. The cost variables include regular workforce cost, hiring cost, firing cost, regular man hours cost, overtime cost, inventory cost, backorder cost and lostsales cost.

With the help of Quantitative Systems (QS) version 3.0, the best method is chosen of the three ones proposed. As it turn out, the Assigned Workforce Levels method proved to be the most applicable, by giving the total cumulative workforce cost per year is 9,945,847 rupiahs, while the total production cost per year for Audio part is 83,723,960 rupiahs, TV part is 133,800,2I6 rupiahs, Rack National is 720,194,496 rupiahs, Rack Sanyo is 764,004,288 rupiahs Rak Mitsubitshi is 836,290,560 rupiahs, MDF 2500 is 887,041,472 rupiahs and MDF 3000 is 1,190,521,440 rupiahs."