Production capacity planning in motorcycle assembly line using CRP method at P T XYZ

Abstract

PT XYZ is an automotive manufacturing company that produces a motorcycle. In an effort to meet the needs of consumers precisely and quickly, PT XYZ deals with problems in terms of fulfilling the capacity in accordance with consumer demand. The problem of imbalanced production capacity occurred in assembly line 3 that produced motorcycle of FU types, consisting of 3 workgroups, namely sub assy, mainline RH, and mainline LH. The imbalance between the capacity and load was due to many work elements of an operator. Thus the load on each work in the three workgroups was greater than the available capacity. This problem was solved using the method of Capacity Requirement Planning/CRP. Based on the result using CRP, the production load of each workgroup was calculated as follows: Sub assy of 115,690 minutes, mainline RH of 186,000 minutes and mainline LH of 218,701 minutes. This result showed an overload capacity in the assembly line and led to a production loss of 868 units in January, 836 units in February, and 867 units in March. It is possible to solve this under loading problem through overtime and work weekends.