Usulan Pengendalian Persediaan Barang Setengah Jadi Dengan Menggunakan Metode Theory Of Constraint (TOC) Melalui Studi Simulasi (Studi Kasus Di PT.Trimandiri Plasindo, Cimahi).

ABSTRAK
PT. Trimandiri Plasindo adalah perusahaan yang bergerak di bidang
pembuatan plastik pembungkus. Plastik pembungkus yang dibuat ada beberapa
jenis, tetapi yang diteliti hanya produk kantong kresek. Saat ini dirasakan bahwa
perusahaan belum dapat memanfaatkan sumber daya secara optimal, terlihat dari
adanya penumpukan persediaan yang berlebih, khususnya pada persediaan barang
setengah jadi. Akibatnya biaya simpan yang timbul relatif tinggi. Biaya simpan
yang tinggi akan berdampak pada meningkatnya biaya produksi. Selain masalah
penumpukan persediaan barang setengah jadi, saat ini perusahaan berencana
untuk memperluas pangsa pasar yang telah dimilikinya. Oleh karena itu,
perusahaan ingin mengukur kapasitas produksi maksimum yang dimiliki agar
perusahaan dapat mengetahui sampai sejauh mana perusahaan dapat memenuhi
permintaan konsumen.
Dalam memecahkan permasalahan yang dihadapi perusahaan, penulis
menggunakan metode Theory of Constraint (TOC) dengan pembuatan model
simulasi dengan bantuan Software Promodel versi 2001. Ada 2 skenario yang
dibuat, skenario pertama digunakan untuk pengendalian jumlah persediaan dan
skenario kedua digunakan untuk melihat seberapa besar kapasitas produksi
maksimum yang dimiliki perusahaan.
Hasil simulasi dengan skenario pertama menunjukkan bahwa jumlah
persediaan barang setengah jadi di departemen potong berkurang dari 1028

menjadi 192 gulung untuk tipe HD-15, untuk HD-24 berkurang dari 789 menjadi
168 gulung, untuk HD-26 berkurang dari 303 menjadi 60 gulung, untuk HD-28
tetap 27 gulung, untuk HD-30 berkurang dari 295 menjadi 42 gulung dan untuk
HD-40 berkurang dari 58 menjadi 30 gulung.
Hasil simulasi dengan skenario kedua menunjukkan bahwa apabila
perusahaan melakukan perluasan pangsa pasar, maka perusahaan akan mampu
memenuhi permintaan yang semula sebanyak 766 karung per bulan menjadi 1.900
karung per bulan untuk tipe HD-15, untuk HD-24 semula sebanyak 1.326 karung
per bulan menjadi 3.266 karung per bulan, untuk HD-26 semula sebanyak 529
karung per bulan menjadi 1.222 karung per bulan, untuk HD-28 semula sebanyak
60 karung per bulan menjadi 67 karung per bulan, untuk HD-30 semula sebanyak
981 karung per bulan menjadi 1.582 karung per bulan, dan untuk HD-40 semula
sebanyak 210 karung per bulan menjadi 542 karung per bulan.

DAFTAR ISI

Halaman
LEMBAR PENGESAHAN .......................................................................

i

ABSTRAK ..................................................................................................

ii

PERNYATAAN HASIL KARYA PRIBADI ...........................................

iii

KATA PENGANTAR DAN UCAPAN TERIMA KASIH .....................

iv

DAFTAR ISI ...............................................................................................

vii

DAFTAR TABEL ......................................................................................

xi

DAFTAR GAMBAR ..................................................................................

xv

DAFTAR LAMPIRAN ..............................................................................

xx

BAB 1 PENDAHULUAN ..........................................................................

1-1

1.1 Latar Belakang Masalah ..........................................................

1-1

1.2 Identifikasi Masalah ...............................................................

1-2

1.3 Batasan Masalah dan Asumsi .................................................

1-2

1.4 Perumusan Masalah ................................................................

1-3

1.5 Tujuan Penelitian .....................................................................

1-3

1.6 Sistematika Penulisan ...............................................................

1-4

BAB 2 TINJAUAN PUSTAKA..................................................................

2-1

2.1 Inventory.....................................................................................

2-1

2.2 Theory Of Constraint .................................................................

2-1

2.2.1 Konsep Dasar TOC ..........................................................

2-1

2.2.2 Prinsip-prinsip yang Mendasari TOC ...........................

2-2

2.2.3 Langkah-langkah TOC....................................................

2-3

2.2.4 Drum, Buffer, Rope...........................................................

2-6

2.2.5 Buffer Management ..........................................................

2-9

2.3 Distribusi Weibull......................................................................

2-11

2.4 Promodel ....................................................................................

2-12

2.4.1 Elemen-elemen Dasar Dalam Promodel ........................

2-12

2.4.2 Parameterisasi Model ......................................................

2-12

2.4.3 Validasi Model..................................................................

2-13

2.4.3.1 Kekompleksan Model ...................................................

2-13

2.4.3.2 Konsep Validasi Model .................................................

2-14

2.5 Pengujian Hipotesis...................................................................

2-17

2.5.1 Hipotesis Statistik.............................................................

2-17

2.5.2 Uji Nilai Tengah ...............................................................

2-17

BAB 3 METODOLOGI PENELITIAN ....................................................

3-1

3.1 Penelitian Pendahuluan ............................................................

3-3

3.2 Identifkasian Masalah .............................................................

3-3

3.3 Pembatasan Masalah dan Asumsi ...........................................

3-4

3.4 Perumusan Masalah ................................................................

3-4

3.5 Tujuan Penelitian......................................................................

3-4

3.6 Tinjauan Pustaka ......................................................................

3-4

3.7 Penentuan Metode Pemecahan Masalah ...............................

3-4

3.8 Pengumpulan Data....................................................................

3-4

3.9 Pengolahan Data dan Analisis .................................................

3-6

3.10 Kesimpulan dan Saran ...........................................................

3-9

BAB 4 PENGUMPULAN DATA ..............................................................

4-1

4.1 Sejarah Perusahaan ..................................................................

4-1

4.2 Struktur Organisasi Perusahaan .............................................

4-2

4.3 Kewajiban dan Wewenang Setiap bagian .............................

4-4

4.4 Tata Letak Lantai Produksi ....................................................

4-6

4.5 Spesifikasi Produk ....................................................................

4-7

4.6 Proses Produksi ........................................................................

4-7

4.6.1 Tahap Pengerolan ...........................................................

4-7

4.6.2 Tahap Pemotongan .........................................................

4-8

4.6.3 Tahap Pengelpongan .......................................................

4-8

4.7 Proses Pengepakan ...................................................................

4-9

4.7.1 Pak Plastik Pembungkus ................................................

4-9

4.7.2 Pengikatan .......................................................................

4-9

4.7.3 Pak Karung ......................................................................

4-9

4.8 Peta Proses Operasi .................................................................

4-10

4.9 Mesin-Mesin yang Digunakan ................................................

4-11

4.10 Kapasitas Gudang dan tempat Persediaan ..........................

4-13

4.11 Data Permintaan ....................................................................

4-14

4.12 Data Persediaan Awal ............................................................

4-16

4.13 Data Kedatangan Biji Plastik ................................................

4-17

4.14 Data Waktu .............................................................................

4-17

4.14.1 Data Waktu Proses ........................................................

4-17

4.14.2 Data Waktu Perpindahan ............................................

4-23

4.15 Data Pengendalian Persediaan ..............................................

4-27

4.16 Data Setup Mesin Rol..............................................................

4-28

BAB 5 PENGOLAHAN DATA DAN ANALISIS ....................................

5-1

5.1 Pengolahan Data .......................................................................

5-1

5.1.1 Perhitungan Jumlah Biji Plastik yang Dibutuhkan......

5-1

5.1.2 Perhitungan Jumlah Biji Plastik dan Pewarna Per
Kedatangan.......................................................................

5-2

5.1.3 Perhitungan Kapasitas Gudang dan Tempat Persedian 5-2
5.1.4 Parameretisasi Model ......................................................

5-3

5.1.4.1 Distribusi Jumlah Permintaan............................

5-3

5.1.4.2 Distribusi Waktu Proses ......................................

5-4

5.1.5 Validasi Model..................................................................

5-5

5.1.5.1 Validasi Proses......................................................

5-6

5.1.5.2 Validasi Output ....................................................

5-11

5.1.6 Penentuan Letak Constraint ............................................

5-19

5.1.7 Perhitungan Jumlah Buffer.............................................

5-26

5.1.8 Pembuatan Skenario........................................................

5-27

5.1.8.1 Skenario Jumlah Buffer Di Departemen Constraint
(Skenario 1)...........................................................

5-27

5.1.8.1.1 Skenario 1A .......................................................

5-29

5.1.8.1.2 Skenario 1B........................................................

5-35

5.1.8.1.3 Skenario 1C .......................................................

5-41

5.1.8.1.4 Skenario 1D .......................................................

5-47

5.1.8.1.5 Skenario 1E........................................................

5-53

5.1.8.1.6 Skenario 1F ........................................................

5-59

5.1.8.1.7 Rangkuman Hasil Skenario 1 ..........................

5-65

5.1.8.2 Skenario Besarnya Kapasitas Produksi Maksimum
(Skenario 2)...........................................................

5-67

5.1.8.2.1 Skenario 2A .......................................................

5-67

5.1.8.2.2 Skenario 2B........................................................

5-71

5.2 Analisis .......................................................................................

5-75

5.2.1 Analisis Penghematan Biaya ..................................

5-75

5.2.2 Analisis Jadwal Setup Mesin Rol ...........................

5-80

5.2.3 Analisis Kapasitas Produksi Maksimum ..............

5-81

5.2.2 Analisis Gudang Barang Jadi ................................

5-82

BAB 6 KESIMPULAN DAN SARAN .......................................................

6-1

6.1 Kesimpulan ................................................................................

6-1

6.2 Saran ..........................................................................................

6-2

DAFTAR PUSTAKA ..................................................................................

xxi

LAMPIRAN.................................................................................................

xxii

DAFTAR TABEL

Tabel

Judul

Halaman

Tabel 2.1

Uji-uji Mengenai Nilaitengah

2-19

Tabel 2.1

Uji-uji Mengenai Nilaitengah (Lanjutan)

2-20

Tabel 4.1

Spesifikasi Masing-Masing Tipe Kantong Kresek

4-7

Tabel 4.2

Jumlah Mesin Rol yang Dipergunakan

4-11

Tabel 4.3

Jumlah Mesin Potong yang Digunakan

4-12

Tabel 4.4

Data Permintaan

4-14

Tabel 4.4

Data Permintaan (Lanjutan)

4-15

Tabel 4.5

Data Persediaan Awal Departemen Potong

4-16

Tabel 4.6

Data Persediaan Awal Gudang Barang Jadi

4-16

Tabel 4.7

Jumlah Kedatangan Karung

4-17

Tabel 4.8

Waktu Proses Rol

4-18

Tabel 4.9

Waktu Proses Potong

4-18

Tabel 4.10

Waktu Proses Plong

4-19

Tabel 4.11

Waktu Proses Packing Pembungkusan

4-20

Tabel 4.12

Waktu Proses Packing Perekatan

4-20

Tabel 4.12

Waktu Proses Packing Perekatan (lanjutan)

4-21

Tabel 4.13

Waktu Proses Pengikatan

4-21

Tabel 4.13

Waktu Proses Pengikatan (lanjutan)

4-22

Tabel 4.14

Waktu Proses Pak Karung

4-22

Tabel 4.15

Waktu Perpindahan Gudang Bahan Baku Ke
Departemen Rol

Tabel 4.16

Waktu Perpindahan Dari Departemen Rol Ke Tempat
WIP Potong

Tabel 4.17

4-24

Waktu Perpindahan Dari Tempat WIP Potong Ke
Departemen Potong Otomatis

Tabel 4.18

4-23

4-24

Waktu Perpindahan Dari Tempat WIP Potong Ke
Departemen Potong Manual

4-25

DAFTAR TABEL

Tabel
Tabel 4.19

Judul

Halaman

Waktu Perpindahan Dari Departemen Potong
Otomatis ke Tempat WIP Packing

Tabel 4.20

4-26

Waktu Perpindahan Dari Departemen Potong Manual
ke Tempat WIP Plong

4-26

Tabel 4.21

Kapasitas Maksimum dan Minimum WIP Potong

4-28

Tabel 5.1

Kebutuhan Biji Plastik

5-1

Tabel 5.2

Kapasitas WIP Potong

5-3

Tabel 5.3

Distribusi Kedatangan Permintaan

5-3

Tabel 5.3

Distribusi Kedatangan Permintaan (lanjutan)

5-4

Tabel 5.4

Data-data untuk Uji Hipotesis

5-11

Tabel 5.5

Persen Utilisasi Departemen Rol

5-23

Tabel 5.6

Persen Utilisasi departemen Potong

5-24

Tabel 5.7

Hasil Perhitungan Time Buffer

5-26

Tabel 5.8

Hasil Perhitungan Buffer

5-27

Tabel 5.9

Jumlah Persediaan Minimal Pada WIP Potong

5-28

Tabel 5.10

Jumlah Buffer Skenario 1A

5-29

Tabel 5.11

Perhitungan Biaya Simpan Skenario 1A

5-33

Tabel 5.12

Perhitungan Biaya Setup Skenario 1A

5-33

Tabel 5.13

Perhitungan Total Biaya yang Diperlukan
Skenario 1A

5-34

Tabel 5.14

Jumlah Buffer Skenario 1B

5-35

Tabel 5.15

Perhitungan Biaya Simpan Skenario 1B

5-39

Tabel 5.16

Perhitungan Biaya Setup Skenario 1B

5-39

Tabel 5.17

Perhitungan Total Biaya yang Diperlukan

Tabel 5.18

Skenario 1B

5-40

Jumlah Buffer Skenario 1C

5-41

DAFTAR TABEL

Tabel

Judul

Halaman

Tabel 5.19

Perhitungan Biaya Simpan Skenario 1C

5-45

Tabel 5.20

Perhitungan Biaya Setup Skenario 1C

5-45

Tabel 5.21

Perhitungan Total Biaya yang Diperlukan
Skenario 1C

5-46

Tabel 5.22

Jumlah Buffer Skenario 1D

5-47

Tabel 5.23

Perhitungan Biaya Simpan Skenario 1D

5-51

Tabel 5.24

Perhitungan Biaya Setup Skenario 1D

5-51

Tabel 5.25

Perhitungan Total Biaya yang Diperlukan
Skenario 1D

5-52

Tabel 5.26

Jumlah Buffer Skenario 1E

5-53

Tabel 5.27

Perhitungan Biaya Simpan Skenario 1E

5-57

Tabel 5.28

Perhitungan Biaya Setup Skenario 1E

5-57

Tabel 5.29

Perhitungan Total Biaya yang Diperlukan
Skenario 1E

5-58

Tabel 5.30

Jumlah Buffer Skenario 1F

5-59

Tabel 5.31

Perhitungan Biaya Simpan Skenario 1F

5-63

Tabel 5.32

Perhitungan Biaya Setup Skenario 1F

5-63

Tabel 5.33

Perhitungan Total Biaya yang Diperlukan
Skenario 1F

5-64

Tabel 5.34

Rangkuman Total Biaya Skenario 1

5-66

Tabel 5.35

Jumlah Buffer yang Digunakan dan Total Biaya

5-66

Tabel 5.36

Persen Utilisasi Departemen Rol Skenario 2A

5-68

Tabel 5.37

Persen Utilisasi Departemen Potong Skenario 2A

5-70

Tabel 5.38

Persen Utilisasi Departemen Rol Skenario 2B

5-72

Tabel 5.39

Kapasitas Mesin Potong yang Digunakan

5-73

Tabel 5.40

Persen Utilisasi Departemen Potong Skenario 2B

5-74

Tabel 5.41

Biaya Simpan WIP Potong Kondisi Aktual

5-79

DAFTAR TABEL

Tabel

Judul

Halaman

Tabel 5.42

Biaya Setup Kondisi Aktual

5-79

Tabel 5.43

Total Biaya Kondisi Aktual

5-80

Tabel 5.44

Penghematan Total Biaya

5-80

Tabel 5.45

Jadwal Produksi Mesin Rol

5-81

Tabel 5.46

Kapasitas Produksi Maksimum

5-82

Tabel 5.47

Peningkatan Throughput Perusahaan

5-82

DAFTAR GAMBAR

Gambar
Gambar 2.1

Judul

Halaman

Aliran Produk dari Work Center A sampai G,
Dimana Work Center D Merupakan Bottleneck.

2-6

Gambar 2.2

Tampilan Kapasitas dari Work Center D

2-7

Gambar 2.3

Jaringan Lintasan Pada Bottleneck

2-9

Gambar 2.4

Hubungan Antara Kekompleksan Model,

Gambar 2.5

Ketepatan Model, dan Biaya Model

2-14

Proses Verifikasi dan Validasi Model

2-15

Gambar 2.6

Wilayah Kritik Bagi Hipotesis Alternatif µ ≠ μ 0

2-18

Gambar 3.1

Metodologi Penelitian

3-1

Gambar 3.1

Metodologi Penelitian (Lanjutan 1)

3-2

Gambar 3.1

Metodologi Penelitian (Lanjutan 2)

3-3

Gambar 3.2

Flow Chart Pengolahan Data dan Analisis

3-6

Gambar 3.2

Flow Chart Pengolahan Data dan Analisis
(Lanjutan)

3-7

Gambar 4.1

Struktur Organisasi Perusahaan

4-3

Gambar 4.2

Tata Letak Lantai Produksi

4-6

Gambar 4.3

Hasil Potongan Plastik

4-8

Gambar 4.4

Hasil Proses Plong

4-8

Gambar 4.5

Peta Proses Operasi Pembuatan Kantong Kresek 4-10

Gambar 5.1

Kurva Uji Normal Kantong Kresek Tipe HD-15

5-12

Gambar 5.2

Kurva Uji Normal Kantong Kresek Tipe HD-24

5-14

Gambar 5.3

Kurva Uji Normal Kantong Kresek Tipe HD-26

5-15

Gambar 5.4

Kurva Uji Normal Kantong Kresek Tipe HD-28

5-16

Gambar 5.5

Kurva Uji Normal Kantong Kresek Tipe HD-30

5-17

Gambar 5.6

Kurva Uji Normal Kantong Kresek Tipe HD-40

5-19

Gambar 5.7

Diagram Persen Utilisasi Departemen Rol

5-23

DAFTAR GAMBAR

Gambar

Judul

Halaman

Gambar 5.8

Diagram Persen Utilisasi Departemen Potong

5-24

Gambar 5.9

Diagram Persen Utilisasi Departemen Packing

5-24

Gambar 5.10

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1A

Gambar 5.11

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1A

Gambar 5.12

5-37

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1B

Gambar 5.21

5-36

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1B

Gambar 5.20

5-36

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1B

Gambar 5.19

5-36

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1B

Gambar 5.18

5-32

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1B

Gambar 5.17

5-32

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1A

Gambar 5.16

5-31

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1A

Gambar 5.15

5-31

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1A

Gambar 5.14

5-30

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1A

Gambar 5.13

5-30

5-37

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1B

5-38

DAFTAR GAMBAR

Gambar
Gambar 5.22

Judul
Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1C

Gambar 5.23

5-50

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1D

Gambar 5.34

5-49

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1D

Gambar 5.33

5-49

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1D

Gambar 5.32

5-48

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1D

Gambar 5.31

5-48

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1D

Gambar 5.30

5-44

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1D

Gambar 5.29

5-44

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1C

Gambar 5.28

5-43

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1C

Gambar 5.27

5-43

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1C

Gambar 5.26

5-42

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1C

Gambar 5.25

5-42

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1C

Gambar 5.24

Halaman

5-50

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1E

5-54

DAFTAR GAMBAR

Gambar
Gambar 5.35

Judul
Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1E

Gambar 5.36

5-62

Diagram Persen Utilisasi Departemen Rol
Skenario 2A

Gambar 5.47

5-62

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1F

Gambar 5.46

5-61

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1F

Gambar 5.45

5-61

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1F

Gambar 5.44

5-60

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1F

Gambar 5.43

5-60

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-24 Skenario 1F

Gambar 5.42

5-56

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-15 Skenario 1F

Gambar 5.41

5-56

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-40 Skenario 1E

Gambar 5.40

5-55

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-30 Skenario 1E

Gambar 5.39

5-55

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-28 Skenario 1E

Gambar 5.38

5-54

Grafik Hasil Simulasi Kantong Kresek Tipe
HD-26 Skenario 1E

Gambar 5.37

Halaman

5-68

Diagram Persen Utilisasi Departemen Potong
Skenario 2A

5-69

DAFTAR GAMBAR

Gambar
Gambar 5.48

Judul
Diagram Persen Utilisasi Departemen Packing
Skenario 2A

Gambar 5.49

5-77

Grafik Persediaan WIP Potong HD-30 Kondisi
Aktual

Gambar 5.57

5-76

Grafik Persediaan WIP Potong HD-28 Kondisi
Aktual

Gambar 5.56

5-76

Grafik Persediaan WIP Potong HD-26 Kondisi
Aktual

Gambar 5.55

5-75

Grafik Persediaan WIP Potong HD-24 Kondisi
Aktual

Gambar 5.54

5-74

Grafik Persediaan WIP Potong HD-15 Kondisi
Aktual

Gambar 5.53

5-73

Diagram Persen Utilisasi Departemen Packing
Skenario 2B

Gambar 5.52

5-72

Diagram Persen Utilisasi Departemen Potong
Skenario 2B

Gambar 5.51

5-71

Diagram Persen Utilisasi Departemen Rol
Skenario 2B

Gambar 5.50

Halaman

5-77

Grafik Persediaan WIP Potong HD-40 Kondisi
Aktual

5-78

DAFTAR LAMPIRAN

Lampiran
LAMPIRAN 1

Judul

Halaman

Sampel Bon Pengeluaran Barang Jadwal
Pesanan

1-1

LAMPIRAN 2

Jarak Perpindahan Material

2-1

LAMPIRAN 3

Waktu Proses per Gulung,
Perhitungan Waktu Perpindahan

3-1

LAMPIRAN 4

Pengujian Distribusi Jumlah Pesanan

4-1

LAMPIRAN 5

Pengujian Distribusi Waktu

5-1

LAMPIRAN 6

Simulasi Kondisi Aktual

6-1

LAMPIRAN 7

Simulasi Skenario 1

7-1

LAMPIRAN 8

Simulasi Skenario 2

8-1

LAMPIRAN 9

Dokumentasi Perusahaan

9-1

LAMPIRAN 10

Tabel Kurva Normal

10-1

Biaya Listrik

10-2

LAMPIRAN 1
Sampel Bon Pengeluaran Barang Jadwal Pesanan

LAMPIRAN 2
Jarak Perpindahan Material

W IP Potong

WC
H D -15

30,95 m
HD-15

26,45 m

13,2 m

H D -24

H D -15

H D -26

14,25 m

16,75 m

7 m

7 m

21,75 m

M anual

20,95 m
H D -24

H D -15

H D -40
13,25 m

23 m
20,75 m
H D -28
H D -24

17 m

W IP Potong
14,75 m
19,75 m

21,5 m
19,5 m

A lat Packing

12 m

18,5 m
25 m
26,25 m
14,75 m

A lat Packing

3,5 m

M eja Packing

Alat Plong

14,5 m

22,25 m
26 m

Ruang
Packing

RUANG PRODUKSI
Mesin Rol
27,15 m

H D -26

H D -30

HD-30

13,4 m

R uang Produksi M esin
Potong
11,5 m

HD-40

HD-24

H D -30

7,7 m

16,95 m

66'-11 1/8"

H D-24

O tom atis

G udang B ahan
Baku
11 m

23 m

HD-28

Ruang G udang Barang
Jadi

18,4 m

0

0

LAMPIRAN 3
Waktu Proses per Gulung
Perhitungan Waktu Perpindahan

Perhitungan Waktu Proses Per Gulung
•

•

Data-data yang Diperlukan
Tipe Kantong

Jmlh/ Pack

Jmlh/ Ikat

Jmlh/ Bal

Berat/Ikat

Berat/

Berat/Bal

Jmlh Ikat/

Jmlh Lembar/

Jmlh Pak/

Kresek

(Lembar)

(Pack)

(Ikat)

(Kg)

Gulung (Kg)

(Kg)

Gulung

Gulung

Gulung

a

b

c

d

e

f

g

h

i=bxcxh

j=i/b

HD 15

100

10

30

1.8

22.5

54

12

12000

120

HD 24

100

10

15

2.9

27.5

43.5

9

9000

90

HD 26

100

10

10

4.2

30

42

7

7000

70

HD 28

100

10

6

6.5

32.5

39

5

5000

50

HD 30

100

10

5

7

40

35

5

5000

50

HD 40

50

5

10

4.25

42.5

42.5

10

2500

50

Waktu Proses Per Gulung
Waktu Proses untuk Kantong Kresek Tipe – (menit)
Proses diHD 15

HD 24

HD 26

HD 28

HD 30

HD 40

M Rol

45

46

48

50

52

50

M Potong Otomatis

138

142

124

126

139

149

M Potong Manual

133

138

121

121

137

146

Proses Pengeplongan
Tipe Kantong
Kresek

Jmlh Ikat/ Gulung

Waktu Proses
per Ikat (dtk)

Waktu Proses per
Gulung (menit)

a

b

c

d=bxc

HD 15

12

26.69

5.34

HD 24

9

26.69

4.00

HD 26

7

26.69

3.11

HD 28

5

26.69

2.22

HD 30

5

26.69

2.22

HD 40

10

26.69

4.45

Proses Pembungkusan Plastik
Tipe Kantong
Kresek

Jmlh Pak/ Gulung

Waktu Proses
per Ikat (dtk)

Waktu Proses per
Gulung (menit)

a

b

c

d=bxc

HD 15

120

8.97

17.94

HD 24

90

8.97

13.46

HD 26

70

8.97

10.47

HD 28

50

8.97

7.48

HD 30

50

8.97

7.48

HD 40

50

8.97

7.48

Proses Perekatan Plastik
Tipe Kantong
Kresek

Jmlh Pak/ Gulung

Waktu Proses
per Ikat (dtk)

Waktu Proses per
Gulung (menit)

a

b

c

d=bxc

HD 15

120

7.66

15.32

HD 24

90

7.66

11.49

HD 26

70

7.66

8.94

HD 28

50

7.66

6.38

HD 30

50

7.66

6.38

HD 40

50

7.66

6.38

Proses Pengikatan
Tipe Kantong
Kresek

Jmlh Ikat/ Gulung

a

Waktu Proses
per Ikat (dtk)

Waktu Proses per
Gulung (menit)

b

c

d=bxc

HD 15

12

55.59

11.12

HD 24

9

55.59

8.34

HD 26

7

55.59

6.49

HD 28

5

55.59

4.63

HD 30

5

55.59

4.63

HD 40

10

55.59

9.27

Proses Packing Karung
Tipe
Kantong
Kresek

Jmlh Ikat/
Bal

Jmlh Ikat/
Gulung

Jmlh
Gulung/ Bal

Waktu
Proses per
Bal (menit)

Waktu Proses
per Gulung
(menit)

a

b

c

d=b/c

e

f=dxe

HD 15

30

12

2.5

3

7.5
5

HD 24

15

9

1.67

3

HD 26

10

7

1.43

3

4.29

HD 28

6

5

1.2

3

3.6

HD 30

5

5

1

3

3

HD 40

10

10

1

3

3

Perhitungan Waktu Perpindahan
Asumsi Waktu perpindahan material adalah 12,57 detik per 8 meter.
Waktu perpindahan = (Jarak / 8 meter) x 12,57 detik
•

Gudang Bahan Baku ke Mesin Rol
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

•

Jarak
(meter)
27.15
13.4
18.4
11
12
14.5

Waktu
Perpindahan
(dtk)
42.66
21.06
28.91
17.29
18.86
22.79

Mesin Rol ke WIP Potong

Waktu perpindahan = ((Jarak / 8 meter) x 12,57 detik) + Wkt penurunan plastik
dari mesin rol

Wkt penurunan plastik dari mesin rol = 60 detik
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

•

Jarak
(meter)
7.7
20.95
30.95
26.45
16.95
13.2

Waktu
Perpindahan
(dtk)
1.20
1.55
1.81
1.69
1.44
1.35

WIP Potong ke Mesin Potong Otomatis

Waktu perpindahan = ((Jarak / 8 meter) x 12,57 detik) + Wkt penurunan plastik
dari mesin rol
Wkt penurunan plastik dari mesin rol = 30 detik
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

•

Jarak
(meter)
7
7
16.75
14.25
-

Waktu
Perpindahan
(dtk)
41
41
56.32
52.39
-

WIP Potong ke Mesin Potong Manual

Waktu perpindahan = ((Jarak / 8 meter) x 12,57 detik) + Wkt penurunan plastik
dari mesin rol
Wkt penurunan plastik dari mesin rol = 30 detik
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

Jarak
(meter)
21.75
23
11.5
20.75
17
13.25

Waktu
Perpindahan
(dtk)
64.18
66.14
48.07
62.61
56.71
50.82

•

Mesin Potong Otomatis ke WIP Packing

Waktu perpindahan = (Jarak / 8 meter) x 12,57 detik
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

•

Jarak
(meter)
19.75
14.75
21.5
19.5
-

Waktu
Perpindahan
(dtk)
31.04
23.18
33.79
30.64

Mesin Potong Manual ke WIP Plong

Waktu perpindahan = (Jarak / 8 meter) x 12,57 detik
Tipe
Kantong
Kresek
HD 15
HD 24
HD 26
HD 28
HD 30
HD 40

•

Jarak
(meter)
25
26.25
14.75
26
22.25
18.5

Waktu
Perpindahan
(dtk)
39.29
41.25
23.18
40.86
34.96
29.07

Packing ke Packing Karung

Waktu perpindahan = (Jarak / 8 meter) x 12,57 detik + Waktu pengangkutan
(3,5 meter / 8 meter) x 12,57 detik + 10 detik
= 15,5 detik

•

Packing Karung ke Gudang Barang Jadi

Waktu perpindahan = (Jarak / 8 meter) x 12,57 detik + Waktu pengangkutan
(23 meter / 8 meter) x 12,57 detik + 10 detik
= 46,14 detik

LAMPIRAN 4
Pengujian Distribusi Jumlah Pesanan

Kantong Kresek HD-15

No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-15
31
26
44
33
24
27
44
27
20
34
12
15
17
23
17
19
17
19
67
35
37
55

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-15
61
48
79
44
42
42
18
42
71
15
25
36
28
24
12
26
8
27
21
29
32
22

LAMPIRAN

Laporan Tugas Akhir 

L4-12

  Universitas Kristen Maranatha 

Kantong Kresek HD-24
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-24

85
67
90
58
56
64
79
73
52
73
34
26
46
40
35
32
53
34
71
58
38
49

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-24

71
66
93
71
39
59
28
86
103
37
44
74
52
33
31
31
20
58
52
63
62
28

LAMPIRAN

Laporan Tugas Akhir 

L4-15

  Universitas Kristen Maranatha 

Kantong Kresek HD-26
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-26

40
48
55
28
25
34
46
36
26
31
18
21
23
25
14
23
18
14
18
13
15
18

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-26

18
15
15
15
11
16
3
16
22
9
12
23
12
10
11
11
8
19
37
29
34
27

Kantong Kresek HD-28
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-28

1
2
5
1
9
1
5
3
1
4
4
2
3
2
4
1
2
2
2
1
3
2

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-28

1
1
3
4
1
3
1
3
2
3
1
2
1
6
2
4
1
1
1
3
3
2

LAMPIRAN

Laporan Tugas Akhir 

L4-21

  Universitas Kristen Maranatha 

Kantong Kresek HD-30
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-30

66
62
77
39
52
66
69
66
51
71
42
52
30
58
30
26
46
32
19
40
15
28

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-30

32
35
27
29
22
32
13
32
47
21
15
48
21
19
24
29
19
56
55
63
57
53

Kantong Kresek HD-40
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Data
Permintaan
HD-40

7
9
19
9
9
6
9
14
8
6
6
7
1
1
1
3
5
3
14
15
16
11

No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Data
Permintaan
HD-40

11
9
14
36
2
9
9
18
7
12
3
12
8
10
4
3
3
4
4
4
10
11

LAMPIRAN 5
Pengujian Distribusi Waktu

Proses Pengeplongan
No

Waktu proses
pengeplongan

No

Waktu proses
pengeplongan

1

24.39

16

24.24

2

26.65

17

28.97

3

25.76

18

27.14

4

29.45

19

26.97

5

25.45

20

28.95

6

25.19

21

26.06

7

28.9

22

26.7

8

24.69

23

27.87

9

25.64

24

29.3

10

27.61

25

25.01

11

22.2

26

25.27

12

28.26

27

24.35

13

28.34

28

28.74

14

29.62

29

24.13

15

26.58

30

28.35

Weibull Distribution

Proses Pembungkusan Menggunakan Plastik
No

waktu proses
pembungkusan

No

waktu proses
pembungkusan

1

9.23

16

10.13

2

10.21

17

9.11

3

8.17

18

10.07

4

7.03

19

7.93

5

10.96

20

10.86

6

8.66

21

7.56

7

7.45

22

7.35

8

10.03

23

10.93

9

7.41

24

8.31

10

10.24

25

10.15

11

9.38

26

10.28

12

8.48

27

7.38

13

10.39

28

9.32

14

8.06

29

8.96

15

7.15

30

8.01

Weibull Distribution

Proses Perekatan Plastik Pembungkus
No

waktu proses
perekatan

No

waktu proses
perekatan

1

7.13

16

8.03

2

8.11

17

9.01

3

9.07

18

9.97

4

4.93

19

5.83

5

8.86

20

9.76

6

6.56

21

7.46

7

5.35

22

5.96

8

8.93

23

9.83

9

5.31

24

6.21

10

9.11

25

8.05

11

8.28

26

9.18

12

7.38

27

7.28

13

9.29

28

8.22

14

5.96

29

6.86

15

6.01

30

7.91

Weibull Distribution

Proses Pengikatan
No

Waktu proses
pengikatan

No

Waktu proses
pengikatan

1

47.04

16

61.46

2

61.31

17

49.23

3

52.17

18

48.18

4

53.21

19

54.06

5

59.56

20

57.68

6

60.33

21

53.39

7

46.73

22

61.71

8

55.19

23

53.22

9

59.87

24

55.76

10

57.26

25

58.81

11

56.72

26

54.96

12

60.67

27

49.1

13

61.34

28

61.39

14

52.28

29

55.24

15

53.44

30

56.37

LAMPIRAN

L4-38

Weibull Distribution

Laporan Tugas Akhir 

  Universitas Kristen Maranatha 

LAMPIRAN 6
Simulasi Kondisi Aktual
• Layout Simulasi

• Input

•

Output

LAMPIRAN
•

L4-41

Layout Simulasi

Laporan Tugas Akhir 

  Universitas Kristen Maranatha 

•

Input

********************************************************************************
*
*
*
Formatted Listing of Model:
*
* E:\DATA\Sherly Works\TA SHERLY\TA FIX\SIMULASI AKTUAL\New Folder\SIMULASI PABRIK AKTUAL FIX OK!!!!!!!!.MOD COBA.MOD
*
*
********************************************************************************
Time Units:
Distance Units:
Initialization Logic:

day
Feet
ACTIVATE Sub1()

********************************************************************************
*
Locations
*
********************************************************************************
Name
------------ROLLAN_15
ROLLAN_15.1
ROLLAN_15.2
ROLLAN_15.3
ROLLAN_15.4
ROLLAN_15.5
ROLLAN_24
ROLLAN_24.1
ROLLAN_24.2
ROLLAN_24.3
ROLLAN_24.4
ROLLAN_24.5
ROLLAN_24.6
ROLLAN_26
ROLLAN_26.1

Cap
-----1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Units
----5
1
1
1
1
1
6
1
1
1
1
1
1
2
1

Stats
----------Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series

Rules
Cost
----------------------- -----------Oldest, , Longest Empty
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, , Longest Empty
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, , Longest Empty
Oldest, ,

*

ROLLAN_26.2
ROLLAN_28
ROLLAN_30
ROLLAN_30.1
ROLLAN_30.2
ROLLAN_40
POTONG_M_15
POTONG_M_15.1
POTONG_M_15.2
POTONG_M_15.3
POTONG_M_15.4
POTONG_M_24
POTONG_M_24.1
POTONG_M_24.2
POTONG_M_24.3
POTONG_M_24.4
POTONG_M_24.5
POTONG_M_24.6
POTONG_M_26
POTONG_M_28
POTONG_M_30
POTONG_O_15
POTONG_O_15.1
POTONG_O_15.2
POTONG_O_24
POTONG_O_24.1
POTONG_O_24.2
POTONG_O_26
POTONG_O_30
POTONG_M_40
PLONG
PLONG.1
PLONG.2
PLONG.3
PACK
PACKING
PACKING.1
PACKING.2

1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
2
2
2
2
2
2
2
2
2
1
1
1
1
6
1
1
1

1
1
2
1
1
1
4
1
1
1
1
6
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
3
1
1
1
1
6
1
1

Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time

Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series

Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,

,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,

Longest Empty

Fewest

Fewest

First
First
First
Fewest
Fewest
First
First
By turn

By turn

PACKING.3
PACKING.4
PACKING.5
PACKING.6
GUDANG_BAHAN
INV_ROLLAN_15
INV_ROLLAN_24
INV_ROLLAN_26
INV_ROLLAN_28
INV_ROLLAN_30
INV_ROLLAN_40
WIP_PLONG
WIP_PACK
IKAT
WIP_IKAT
GUDANG_BARANG
WIP_KARUNG
BHN_BAKU_15
BHN_BAKU_24
BHN_BAKU_26
BHN_BAKU_28
BHN_BAKU_30
BHN_BAKU_40
TEMPAT_KARUNG
KARUNG_HD_15
KARUNG_HD_24
KARUNG_HD_26
KARUNG_HD_28
KARUNG_HD_30
KARUNG_HD_40
ORDERAN
PT_15
PT_24
PT_26
PT_28
PT_30
PT_40

1
1
1
1
160000
1038
801
307
27
299
60
4500
4500
2
4500
4687
4500
1
1
1
1
1
1
20000
1
1
1
1
1
1
INF
1
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time

Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series

Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,

,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,

First
First
First
First

********************************************************************************
*
Entities
*
********************************************************************************
Name
-----------HD_15
HD_24
HD_26
HD_28
HD_30
HD_40
BIJI_PLASTIK
PEWARNA
PESANAN
KARUNG_15
KARUNG_24
KARUNG_26
KARUNG_28
KARUNG_30
KARUNG_40

Speed (fpm)
-----------150
150
150
150
150
150
150
150
150
150
150
150
150
150
150

Stats
Cost
----------- -----------Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series

********************************************************************************
*
Path Networks
*
********************************************************************************
Name
Type
T/S
From
-------- ----------- ---------------- -------Net1
Passing
Time
N1
N1
N1
N1
N1
N2
N3
N4

To
-------N2
N3
N4
N5
N6
N8
N8
N8

BI
---Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi

Dist/Time Speed Factor
---------- -----------0 SEC
0 SEC
0 SEC
0 SEC
0 SEC
1.20 MIN
1.55 MIN
1.81 MIN

Net2

Passing

Time

N6
N5
N1
N7
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
N15

N8
N8
N7
N8
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
N13
N13
N13
N13
N14
N14
N14
N14
N14
N14
N16

Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi
Bi

1.44 MIN
1.69 MIN
0 SEC
1.35 MIN
41 SEC
41 SEC
52.39 SEC
56.32 SEC
64.18 SEC
66.14 SEC
48.07 SEC
62.61 SEC
56.71 SEC
50.82 SEC
31.04 SEC
23.18 SEC
30.64 SEC
33.79 SEC
39.29 SEC
41.25 SEC
23.18 SEC
40.86 SEC
34.96 SEC
29.07 SEC
46.14 SEC

********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
---------- ---------Net1
N1
N1
N1
N1
N1
N1
N2
N3
N4
N5
N6
N7
N8
N8
N8
N8
N8
N8
Net2
N3
N4
N5
N6
N8
N9
N10
N11
N12
N13
N14
N15
N15
N15

Location
------------BHN_BAKU_15
BHN_BAKU_24
BHN_BAKU_26
BHN_BAKU_28
BHN_BAKU_30
BHN_BAKU_40
ROLLAN_15
ROLLAN_24
ROLLAN_26
ROLLAN_28
ROLLAN_30
ROLLAN_40
INV_ROLLAN_15
INV_ROLLAN_24
INV_ROLLAN_26
INV_ROLLAN_28
INV_ROLLAN_30
INV_ROLLAN_40
POTONG_O_15
POTONG_O_24
POTONG_O_30
POTONG_O_26
POTONG_M_24
POTONG_M_26
POTONG_M_28
POTONG_M_30
POTONG_M_40
WIP_PACK
WIP_PLONG
KARUNG_HD_15
KARUNG_HD_24
KARUNG_HD_26

N15
N15
N15
N16
N2
N2
N2
N2
N2
N2
N7

KARUNG_HD_28
KARUNG_HD_30
KARUNG_HD_40
GUDANG_BARANG
PT_15
PT_24
PT_26
PT_28
PT_30
PT_40
POTONG_M_15

********************************************************************************
*
Resources
*
********************************************************************************
Res
Name
Units Stats
Search
-------- ----- -------- -----OP_pack 12
By Unit None

Ent
Search Path
Motion
Cost
------ ---------- -------------- -----------Oldest
Empty: 150 fpm
Full: 150 fpm

********************************************************************************
*
Processing
*
********************************************************************************
Process
Entity
Location
Operation
------------ ------------- -----------------PEWARNA
GUDANG_BAHAN

Routing
Blk Output
Destination
Rule
---- ------------ ------------- -------1
PEWARNA
BHN_BAKU_15
FIRST 1

Move Logic
-----------MOVE FOR 0

PEWARNA

BHN_BAKU_24

FIRST

MOVE FOR 0

PEWARNA

BHN_BAKU_26

FIRST

MOVE FOR 0

BIJI_PLASTIK GUDANG_BAHAN

PEWARNA

BHN_BAKU_15

1

BHN_BAKU_24

BHN_BAKU_28

FIRST

MOVE FOR 0

PEWARNA

BHN_BAKU_30

FIRST

MOVE FOR 0

PEWARNA

BHN_BAKU_40

FIRST

MOVE FOR 0

BIJI_PLASTIK
BIJI_PLASTIK
BIJI_PLASTIK
BIJI_PLASTIK
BIJI_PLASTIK
BIJI_PLASTIK

BHN_BAKU_15
BHN_BAKU_24
BHN_BAKU_26
BHN_BAKU_28
BHN_BAKU_30
BHN_BAKU_40

JOIN 1
JOIN
JOIN
JOIN
JOIN
JOIN

MOVE
MOVE
MOVE
MOVE
MOVE
MOVE

JOIN 9 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_15 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_15
ROUTE 2
}
1
BIJI_PLASTIK ROLLAN_15
FIRST 1
2

PEWARNA

PEWARNA

BIJI_PLASTIK ROLLAN_15

SEND 1

JOIN 11 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_24 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_24
ROUTE 2
}
1
BIJI_PLASTIK ROLLAN_24
FIRST 1
2
BIJI_PLASTIK ROLLAN_24
SEND 1

FOR
FOR
FOR
FOR
FOR
FOR

0
0
0
0
0
0

MOVE ON Net1
MOVE ON Net1

MOVE ON Net1
MOVE ON Net1

PEWARNA

PEWARNA

PEWARNA

PEWARNA

BHN_BAKU_26

BHN_BAKU_28

BHN_BAKU_30

BHN_BAKU_40

JOIN 12 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_26 =
{
ROUTE 1
}
ELSE
{
DEC STOP_26
ROUTE 2
}
1
BIJI_PLASTIK ROLLAN_26
2
BIJI_PLASTIK ROLLAN_26
JOIN 13 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_28 =
{
ROUTE 1
}
ELSE
{
DEC STOP_28
ROUTE 2
}
1
BIJI_PLASTIK ROLLAN_28
2
BIJI_PLASTIK ROLLAN_28
JOIN 16 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_30 =
{
ROUTE 1
}
ELSE
{
DEC STOP_30
ROUTE 2
}
1
BIJI_PLASTIK ROLLAN_30
2
BIJI_PLASTIK ROLLAN_30
JOIN 17 BIJI_PLASTIK
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_40 =
{
ROUTE 1
}

0 THEN

FIRST 1
SEND 1

MOVE ON Net1
MOVE ON Net1

0 THEN

FIRST 1
SEND 1

MOVE ON Net1
MOVE ON Net1

0 THEN

FIRST 1
SEND 1
0 THEN

MOVE ON Net1
MOVE ON Net1

ELSE
{
DEC STOP_40
ROUTE 2
}
BIJI_PLASTIK ROLLAN_15

1
2

BIJI_PLASTIK ROLLAN_40
BIJI_PLASTIK ROLLAN_40

FIRST 1
SEND 1

MOVE ON Net1
MOVE ON Net1

WAIT 45 MIN
IF (CONTENTS(INV_ROLLAN_15) < 1028) and RuleRoute_15 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC RuleRoute_15
ROUTE 2
}
1

HD_15

INV_ROLLAN_15 FIRST 1
MOVE ON Net1

2

HD_15

INV_ROLLAN_15 SEND 1
MOVE ON Net1

BIJI_PLASTIK ROLLAN_24

WAIT 46 MIN
IF (CONTENTS(INV_ROLLAN_24) < 789) and RuleRoute_24 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC RuleRoute_24
ROUTE 2
}
1
HD_24
INV_ROLLAN_24 FIRST 1
MOVE ON Net1
2

HD_24

INV_ROLLAN_24 SEND 1
MOVE ON Net1

BIJI_PLASTIK ROLLAN_26

WAIT 48 MIN
IF (CONTENTS(INV_ROLLAN_26) < 303) and RuleRoute_26 = 0 THEN

{
ROUTE 1
}
ELSE
{
DEC RuleRoute_26
ROUTE 2
}

1

HD_26

INV_ROLLAN_26 FIRST 1

2

HD_26

INV_ROLLAN_26 SEND 1

MOVE ON Net1
MOVE ON Net1
BIJI_PLASTIK ROLLAN_28

WAIT 50 MIN
IF (CONTENTS(INV_ROLLAN_28) < 25) and RuleRoute_28 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC RuleRoute_28
ROUTE 2
}
1
HD_28
INV_ROLLAN_28 FIRST 1
MOVE ON Net1
2

HD_28

INV_ROLLAN_28 SEND 1
MOVE ON Net1

BIJI_PLASTIK ROLLAN_30

WAIT 52 MIN
IF (CONTENTS(INV_ROLLAN_30) < 295) and RuleRoute_30 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC RuleRoute_30
ROUTE 2
}
1
HD_30
INV_ROLLAN_30 FIRST 1
MOVE ON Net1
2

HD_30

INV_ROLLAN_30 SEND 1
MOVE ON Net1

BIJI_PLASTIK ROLLAN_40

WAIT 50 MIN
IF (CONTENTS(INV_ROLLAN_40) < 58) and RuleRoute_40 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC RuleRoute_40
ROUTE 2
}
1
HD_40
INV_ROLLAN_40 FIRST 1
MOVE ON Net1
2

HD_40

INV_ROLLAN_40 SEND 1
MOVE ON Net1

HD_15

INV_ROLLAN_15 IF CONTENTS(INV_ROLLAN_15) >= 1028 THEN
{
RuleRoute_15 = 5
Henti_15 = 1
}
1

HD_15

PT_15

FIRST 1

IF (CONTENTS(INV_ROLLAN_15) =

192) and (Henti_15 = 1) THEN
{ WAIT 120 MIN
WAIT 45 MIN
SEND 5 HD_15 TO INV_ROLLAN_15
Henti_15 = 0
}
HD_24

INV_ROLLAN_24 IF CONTENTS(INV_ROLLAN_24) >= 789 THEN
{
RuleRoute_24 = 6
Henti_24 = 1
}
1

180) and (Henti_24 = 1) THEN

HD_24

PT_24

FIRST 1

IF (CONTENTS(INV_ROLLAN_24) =

{ WAIT 120 MIN
WAIT 46 MIN
SEND 6 HD_24 TO INV_ROLLAN_24
Henti_24 = 0
}
HD_26

INV_ROLLAN_26 IF CONTENTS(INV_ROLLAN_26) >= 303 THEN
{
RuleRoute_26 = 2
Henti_26 = 1
}
1

HD_26

PT_26

FIRST 1

IF (CONTENTS(INV_ROLLAN_26) = 60)

and (Henti_26 = 1) THEN
{ WAIT 120 MIN
WAIT 48 MIN
SEND 2 HD_26 TO INV_ROLLAN_26
Henti_26 = 0
}
HD_28

INV_ROLLAN_28 IF CONTENTS(INV_ROLLAN_28) >= 25 THEN
{
RuleRoute_28 = 1
Henti_28 = 1
}
1
HD_28
and (Henti_28 = 1) THEN

PT_28

FIRST 1

IF (CONTENTS(INV_ROLLAN_28) = 6)
{ WAIT 120 MIN
WAIT 50 MIN
SEND 1 HD_28 TO INV_ROLLAN_28
Henti_28 = 0
}

HD_30

INV_ROLLAN_30 IF CONTENTS(INV_ROLLAN_30) >= 295 THEN
{
RuleRoute_30 = 2

Henti_30 = 1
}
1

HD_30

PT_30

FIRST 1

IF (CONTENTS(INV_ROLLAN_30) = 50)

and (Henti_30 = 1) THEN
{ WAIT 120 MIN
WAIT 52 MIN
SEND 2 HD_30 TO INV_ROLLAN_30
Henti_30 = 0
}
HD_40

INV_ROLLAN_40 IF CONTENTS(INV_ROLLAN_40) >= 58 THEN
{
RuleRoute_40 = 1
Henti_40 = 1
}
1

HD_40

PT_40

FIRST 1

IF (CONTENTS(INV_ROLLAN_40) = 12)

and (Henti_40 = 1) THEN
{

WAIT 120 MIN
WAIT 50 MIN
SEND 1 HD_40 TO INV_ROLLAN_40
Henti_40 = 0

}
HD_15

PT_15

IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_15 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_15
ROUTE 2
}
1
HD_15
POTONG_O_15
FIRST 1
HD_15

POTONG_M_15

FIRST

MOVE ON Net2
MOVE ON Net2

2
HD_24

HD_26

HD_28

PT_24

PT_26

PT_28

HD_15
HD_15

POTONG_O_15
POTONG_M_15

SEND 1
SEND

IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_24 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_24
ROUTE 2
}
1
HD_24
POTONG_O_24
FIRST 1
HD_24
POTONG_M_24
FIRST
2
HD_24
POTONG_O_24
SEND 1
HD_24
POTONG_M_24
SEND
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_26 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_26
ROUTE 2
}
1
HD_26
POTONG_O_26
FIRST 1
HD_26
POTONG_M_26
FIRST
2
HD_26
POTONG_O_26
SEND 1
HD_26
POTONG_M_26
SEND
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_28 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_28

MOVE ON Net2
MOVE ON Net2

MOVE
MOVE
MOVE
MOVE

ON
ON
ON
ON

Net2
Net2
Net2
Net2

MOVE
MOVE
MOVE
MOVE

ON
ON
ON
ON

Net2
Net2
Net2
Net2

ROUTE 2
}
HD_30

HD_40

HD_15

HD_24

HD_26

PT_30

PT_40

POTONG_O_15

POTONG_O_24

POTONG_O_26

1
HD_28
POTONG_M_28
FIRST 1
2
HD_28
POTONG_M_28
SEND 1
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_30 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_30
ROUTE 2
}
1
HD_30
POTONG_O_30
FIRST 1
HD_30
POTONG_M_30
FIRST
2
HD_30
POTONG_O_30
SEND 1
HD_30
POTONG_M_30
SEND
IF (CONTENTS(GUDANG_BARANG) < 4600) and STOP_40 = 0 THEN
{
ROUTE 1
}
ELSE
{
DEC STOP_40
ROUTE 2
}
1
HD_40
POTONG_M_40
FIRST 1
2
HD_40
POTONG_M_40
SEND 1
WAIT 138 MIN
1
HD_15
WIP_PACK
FIRST 12

MOVE ON Net2
MOVE ON Net2

MOVE
MOVE
MOVE
MOVE

ON
ON
ON
ON

Net2
Net2
Net2
Net2

MOVE ON Net2
MOVE ON Net2
GRAPHIC 3
MOVE ON Net2

WAIT 142 MIN
1

HD_24

WIP_PACK

FIRST 9

GRAPHIC 3
MOVE ON Net2

1

HD_26

WIP_PACK

FIRST 7

GRAPHIC 3

WAIT 124 MIN

MOVE ON Net2
HD_30

HD_40

POTONG_O_30

POTONG_M_40

WAIT 139 MIN

POTONG_M_15

WAIT 133 MIN

HD_24

POTONG_M_24

WAIT 138 MIN

HD_28

HD_30

ALL
ALL

POTONG_M_26

POTONG_M_28

POTONG_M_30

WIP_PLONG
PLONG

HD_30

WIP_PACK

FIRST 5

GRAPHIC 3
MOVE ON Net2

1

HD_40

WIP_PLONG

FIRST 10

GRAPHIC 3
MOVE ON Net2

1

HD_15

WIP_PLONG

FIRST 12

GRAPHIC 2
MOVE ON Net2

1

HD_24

WIP_PLONG

FIRST 9

GRAPHIC 2
MOVE ON Net2

1

HD_26

WIP_PLONG

FIRST 7

GRAPHIC 2
MOVE ON Net2

1

HD_28

WIP_PLONG

FIRST 5

GRAPHIC 2
MOVE ON Net2

1

HD_30

WIP_PLONG

FIRST 5

GRAPHIC 2
MOVE ON Net2

1

ALL

PLONG

FIRST 1

MOVE FOR 0

WIP_PACK

FIRST 1

GRAPHIC 3
MOVE FOR 0

WAIT 146 MIN

HD_15

HD_26

1

WAIT 121 MIN

WAIT 121 MIN

WAIT 137 MIN

USE OP_pack FOR W(16.2443, 27.5757)SEC
1

ALL

ALL

WIP_PACK

ALL

PACK

HD_15

HD_24

PACKING

PACKING

1
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE
USE

OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack

FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR

ALL

PACK

FIRST 1

MOVE FOR 0

W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
W(8.20858, 9.52208)SEC
1
ALL
PACKING

FIRST 1

MOVE FOR 0

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_15
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

USE OP_pack FOR W(6.18294, 8.26316)SEC
USE OP_pack FOR W(6.18294, 8.26316)SEC
USE OP_pack FOR W(6.18294, 8.26316)SEC
USE OP_pack FOR W(6.18294, 8.26316)SEC
USE OP_pack FOR W(6.18294, 8.26316)SEC
USE OP_pack FOR W(6.18294, 8.26316)SEC

USE
USE
USE
USE

HD_26

HD_28

PACKING

PACKING

USE
USE
USE
USE
USE
USE
USE
USE
USE
USE

USE
USE
USE
USE
USE
USE
USE
USE
USE
USE

OP_pack
OP_pack
OP_pack
OP_pack

OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack

OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack

FOR
FOR
FOR
FOR

FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR

FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_24
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_26
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_28
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

HD_30

HD_40

ALL
ALL

HD_15

PACKING

PACKING

WIP_IKAT
IKAT

WIP_KARUNG

USE
USE
USE
USE
USE
USE
USE
USE
USE
USE

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_30
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
W(6.18294, 8.26316)SEC
1
HD_40
WIP_IKAT

FIRST 1

GRAPHIC 4
MOVE FOR 0

1
ALL
IKAT
USE OP_pack FOR W(9.51749, 37.5274)SEC

FIRST 1

MOVE FOR 0

1

FIRST 1

MOVE FOR 0

USE
USE
USE
USE
USE
USE
USE
USE
USE
USE

OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack

OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack
OP_pack

ACCUM 6

FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR

FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR

ALL

WIP_KARUNG

HD_24

HD_26

HD_28

HD_30

HD_40

1

HD_15

KARUNG_HD_15

JOIN 1

MOVE FOR 15.5 SEC

1

HD_24

KARUNG_HD_24

JOIN 1

MOVE FOR 15.5 SEC

1

HD_26

KARUNG_HD_26

JOIN 1

MOVE FOR 15.5 SEC

1

HD_28

KARUNG_HD_28

JOIN 1

MOVE FOR 15.5 SEC

1