Increasing Productivity in Process of Surface Grinding Piston Ring Parts of Air Conditioner Compressor by Analyzing to Determine Number of Labors Suitable for Machine
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Abstract
The sample company is a contractor of compressor piston ring parts for an air conditioner manufacturing company. The production process is the process of grinding the inner hole of the ring to have a size of 20.6±0.05 mm and a resolution of 0.3 micrometers according to customer requirements, 500 pieces/day. The production process requires 2 workers working with 2 automatic milling machines. Cycle time is 105 seconds/piece, capacity is 257 pieces/day/machine. From the data collection and analysis by multiplicative activity charts for man-machine type, it was found that in each cycle, employees had 61 seconds of idle time per production cycle as 41.90 %, productivity before improvement as 0.0095 pieces/second/person. This research aims to improve the work process of employees to increase productivity in the compressor piston ring manufacturing process. Industrial engineering tools consisted of 7 waste improvement principles, multiple activity charts and man-machine type were therefore used to analyze to consider the workload of each employee. Then use the equation to calculate the maximum number of machines the operator can control. To lead to improvements in working methods to reduce the number of employees that are unnecessary. From the calculations, it is found that the maximum number of machines that is 1 employee can control to 2 machines. It is found that the idle time from work of employees decreased from 61 seconds/cycle time to 7 seconds/ cycle time, decreasing 54 seconds/cycle time. representing a decrease of 88.52 %. The utility value or percentage of the amount of time that employees can work increases from 41.90 % to 186.67 % with the percentage of time that the machine can actually work at 82.07 % and can increase productivity, and it can be increased from 34.27 pieces/hour/person to 68.54 pieces/hour/person, an increase of 34.27 pieces/hour/person, accounted for 100 %
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