THE EFFECT OF LOT SIZE AND PRODUCT STRUCTURE ON MAKESPAN MINIMIZATION IN MULTILEVEL PRODUCT SCHEDULING

Carolina, Maya (2008) THE EFFECT OF LOT SIZE AND PRODUCT STRUCTURE ON MAKESPAN MINIMIZATION IN MULTILEVEL PRODUCT SCHEDULING. S1 thesis, UAJY.

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Abstract

Scheduling is one of the important. parts of manufacturing and engineering. There are a lot of factors should be considered before taking the best scheduling approaches. The Production System Laboratory of UAJY has a long-term research project about the effect of product structure complexity, process routing complexity, and setup time-run time ratio on makespan minimization in multilevel product scheduling. The writer takes a part of this long-term research project. The writer concerns to product structure which is limited on 3 levels and maximum 3 parts in one level. The objective of this research is to define the optimum lot size by evaluating the effect of product structure complexity. There are 6 possible combinations of product structure which have been generated. The routing file is generated to shows step-by-step set of instructions describing how the product is made. The routing files generated to create 5 replications for each product structure, all routing files have the same operations and work centers, the difference is on setup time and run time according to the random number generation. Makespan is found by Gantt chart simulation using Microsoft Excel program. There are several lot size examined, they are 4, 8, 16, and 32. Setup-run time ratio is the function of lot setup time divided by lot size times unit run time. Setup-run time ratio represents optimum lot size in ANOVA test. Based on Gantt chart simulation, every case has its own optimum lot size; number of optimum lot size is randomly distributed. Most of optimum lot size is defined when lot size = 8 or lot size = 16. Based on ANOVA Single Factor result, writer concludes that there is no significant difference between variation of product structure and optimum lot size.

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