Underutilization of machines

Oct 13, 2025 by leolavanderia.com.br 3 views

Introduction

In the increasingly competitive industrial landscape, PT. Atmindo, a boiler manufacturing company, faces significant challenges in increasing production efficiency. The company's current scheduling system, First Come First Serve (FCFS), often results in underutilized machines and overtime, leading to additional costs and decreased productivity. To address this issue, this study aims to design a more efficient scheduling system using the Heuristic Pour method, which considers various factors such as process time, due date, and resource availability.

Background

PT. Atmindo, as a boiler manufacturing company, plays a crucial role in meeting the energy demands of various industries. However, the company's current scheduling system, FCFS, has several limitations. The FCFS system prioritizes orders based on their arrival time, without considering other important factors such as machine availability and process time. This approach often leads to:

Underutilization of machines: Machines are not used optimally, resulting in idle time and decreased productivity.
Overtime costs: The company incurs additional costs due to overtime, which can be avoided with a more efficient scheduling system.
Delays in shipping: The company may struggle to meet due date orders, leading to delays in shipping and potential losses.

Methodology

To address the limitations of the FCFS system, this study proposes the use of the Heuristic Pour method, a scheduling technique that considers various factors such as process time, due date, and resource availability. The Heuristic Pour method is designed to produce an optimal production schedule, which can help PT. Atmindo increase efficiency, reduce overtime costs, and improve timeliness of shipping.

Indicators for Assessing Effectiveness

This study uses several indicators to assess the effectiveness of the Heuristic Pour method, including:

Efficiency Index (EI)

The Efficiency Index (EI) measures the level of efficiency of machine use in completing orders. A higher EI indicates that machines are being used more optimally, resulting in increased productivity and reduced idle time.

Relative Error (RE)

The Relative Error (RE) measures the level of error in meeting due date orders. A lower RE indicates that the company is better able to meet due date orders, resulting in improved timeliness of shipping and reduced delays.

Overtime Costs

Overtime costs are an important indicator of the effectiveness of the Heuristic Pour method. By reducing overtime frequency and duration, the company can save operational costs and improve productivity.

Expected Outcomes

The results of this study are expected to produce an optimal boiler production schedule planning, with the aim of:

Increasing the Efficiency of Machine Use

The Heuristic Pour method is expected to increase the efficiency of machine use, resulting in reduced idle time and increased productivity.

Minimizing Overtime Costs

By producing a more efficient production schedule, the company can reduce overtime frequency and save operational costs.

Increasing the Timeliness of Shipping

The Heuristic Pour method helps determine the more accurate workmanship time, enabling the company to meet due date orders better and improve timeliness of shipping.

Conclusion

The application of the Heuristic Pour method at PT. Atmindo has great potential to increase the efficiency of boiler production, enabling the company to compete more competitively in the market. This study can also serve as a reference for other manufacturing companies seeking to improve their production efficiency by applying more optimal scheduling methods.

Recommendations

Based on the expected outcomes of this study, the following recommendations are made:

Implement the Heuristic Pour method: PT. Atmindo should implement the Heuristic Pour method to produce an optimal production schedule.
Monitor and evaluate performance: The company should regularly monitor and evaluate the performance of the Heuristic Pour method to ensure its effectiveness.
Continuously improve the scheduling system: The company should continuously improve the scheduling system by incorporating new techniques and technologies to maintain its competitive edge.

Limitations

This study has several limitations, including:

Limited scope: The study focuses on PT. Atmindo and may not be applicable to other companies with different production processes and scheduling systems.
Data limitations: The study relies on historical data, which may not accurately reflect the current production environment.
Implementation challenges: The implementation of the Heuristic Pour method may face challenges, such as resistance to change and lack of resources.

Future Research Directions

This study provides a foundation for future research in the area of production scheduling. Some potential research directions include:

Comparative analysis of scheduling methods: A comparative analysis of different scheduling methods, including the Heuristic Pour method, to determine their effectiveness in various production environments.
Development of new scheduling techniques: The development of new scheduling techniques that can adapt to changing production environments and improve productivity.
Implementation of scheduling systems: The implementation of scheduling systems in various industries to improve productivity and reduce costs.
Frequently Asked Questions (FAQs) about Comparative Analysis of Priority Rules for Production Scheduling at PT. Atmindo =====================================================================================

Q: What is the main objective of this study?

A: The main objective of this study is to design a more efficient scheduling system for PT. Atmindo's boiler production using the Heuristic Pour method, which considers various factors such as process time, due date, and resource availability.

Q: What are the limitations of the current scheduling system (FCFS)?

A: The FCFS system prioritizes orders based on their arrival time, without considering other important factors such as machine availability and process time. This approach often leads to underutilization of machines, overtime costs, and delays in shipping.

Q: What are the expected outcomes of this study?

A: The expected outcomes of this study are:

Increasing the efficiency of machine use: The Heuristic Pour method is expected to increase the efficiency of machine use, resulting in reduced idle time and increased productivity.
Minimizing overtime costs: By producing a more efficient production schedule, the company can reduce overtime frequency and save operational costs.
Increasing the timeliness of shipping: The Heuristic Pour method helps determine the more accurate workmanship time, enabling the company to meet due date orders better and improve timeliness of shipping.

Q: What are the indicators used to assess the effectiveness of the Heuristic Pour method?

A: The indicators used to assess the effectiveness of the Heuristic Pour method are:

Efficiency Index (EI): Measures the level of efficiency of machine use in completing orders.
Relative Error (RE): Measures the level of error in meeting due date orders.
Overtime costs: Shows additional costs incurred due to overtime.

Q: What are the potential benefits of implementing the Heuristic Pour method at PT. Atmindo?

A: The potential benefits of implementing the Heuristic Pour method at PT. Atmindo include:

Increased competitiveness: The company can compete more competitively in the market by increasing efficiency and reducing costs.
Improved productivity: The Heuristic Pour method can help reduce idle time and increase productivity.
Better customer satisfaction: The company can meet due date orders better and improve timeliness of shipping, leading to better customer satisfaction.

Q: What are the potential challenges of implementing the Heuristic Pour method at PT. Atmindo?

A: The potential challenges of implementing the Heuristic Pour method at PT. Atmindo include:

Resistance to change: Employees may resist the change to a new scheduling system.
Lack of resources: The company may not have the necessary resources to implement and maintain the Heuristic Pour method.
Data limitations: The study relies on historical data, which may not accurately reflect the current production environment.

Q: What are the future research directions for this study?

A: Some potential future research directions for this study include:

Comparative analysis of scheduling methods: A comparative analysis of different scheduling methods, including the Heuristic Pour method, to determine their effectiveness in various production environments.
Development of new scheduling techniques: The development of new scheduling techniques that can adapt to changing production environments and improve productivity.
Implementation of scheduling systems: The implementation of scheduling systems in various industries to improve productivity and reduce costs.