Improving Work Efficiency and Productivity with Line Balancing and TPS Approach and Promodel Simulation on Brush Sub Assy Line in Automotive Companies

Abstract

From Gaikindo’s data, the impact of the covid-19 effect caused the automotive industry to experience a 50% contraction; PT Denso Indonesia, which is an automotive component company, felt the impact where actual production fell by 30% in the first quartile of 2020, the company’s adaptation was efficiency and productivity and activity cost down. The problem with the starter line is that there is a difference in the cycle time of each post in the sub-assy starter brush line, too gaping. From this problem, the researchers analyzed with the TPS and Line Balancing methods with the help of pro model simulations, from these activities evaluated the performance line from the previous line efficiency of 89.05% Balance Delay: 10.95% and Smoothie Index 12.58 improved to line efficiency of 93.59% Balance Delay: 6.35% and Smoothie Index 6.10. However, there are still bottlenecks, following which improvements will be made using line balancing with pro model simulations; pro model simulations were chosen because to make repairs, it is enough to use the help of applications that are in line with the goals of the company, which is currently survival amid this intense competition. After the repair was done using the Helgerson Bernie approach, a simulation of the line balancing method improvement was carried out. The line efficiency value was 95.76% Balance Delay: 4.24% and Smoothie Index 4.45 with a total outflow of 131 units of goods every 1 hour.