Truck Assembly Line Reconfiguration to Reduce Cycle Time with Lean Manufacturing Approach in the Indonesian Automotive Industry

Abstract

The automotive industry is one of the industries that plays a major role in Indonesia's revenue sources, one of which is in meeting daily needs, especially for transportation and logistics. This causes the growth of truck production targets each year and has become one of Indonesia's focus to target 1.29 million trucks produced in 2020. This study aims to minimize production time with the optimal number of workstations to minimize costs that will come out for increasing production capacity in truck assembly lines in Indonesia. The study was conducted with a lean manufacturing approach to analyze the waste contained in the assembly line. The study began by calculating time for each work using the time study method. The time obtained is then inputted to the mixed integer linear programming mathematical programming model developed in the LINGO 17.0 software. The result of data processing in the LINGO 17.0 software is the allocation of each job to the new workstation to get the production cycle time in accordance with the production takt time, and also the total idle time of the new assembly line.