Production Flow Optimization By Using Theory of Constraints

Abstract

The use of Theory of Constraints (ToC) is very necessary in overcoming problems in the production automation system in the industry. This research aims to overcome the rate of instant noodle production automatically in the factory. The study was conducted in a national company that produces instant noodles at Tanjung Morawa, North Sumatera, Indonesia. The experience of constraints of bottlenecks were observed at mixing station and cooking station caused by the different capacities between the work stations. This research uses the principle of continuous improvement. A linear programming method is used to optimize master production schedule (MPS) and determine the maximum throughput. The results showed that applying the theory of constraint in the flow rate can solve the problems in the production of instant noodle in the factory. The ToC eliminate the constraints on the bottleneck work stations so that the overall production flow can run effectively and efficiently. After optimal MPS results has been known, rough-cut capacity planning (RCCP) revisions are calculated and the results showed that the bottleneck work stations have become non-bottleneck work stations, and the maximum throughput has been achieved.