PT. Bakrie Tosanjaya is a foundry company, which initially manufactured pipefittings and sockets. When it then produced spare parts for automotive components like brake drum, flywheel, air brake coupling, and other general castings, the plant layout and production process had been modified to accommodate these new products. Of course there are always problems occurred because of these modifications. Apart of them is the efficiency in the production line itself. Since the demand of the products is very much influenced by the automotive business, which is cyclical, the company is facing shortage in production capacity during high demand season and excess capacity and manpower during low demand season. This Group Field Project has been designed to handle these kinds of problem.

The company is currently running their production line with two mix mulIers, three moulding machines and produces three size categories of product. The focus of this project is in improving the efficiency of the moulding machine. The method used here is improving the production efficiency through the simulation program SIMAN IV MicroLab IV Vsn. 1.3b from Systems Modeling Corporation, which is constructed to assemble real production process with current production data. Since we have limited of time, the simulation is only done on Sinto line with category I product with the objective is to improve the production rate of Sinto moulding machine given the limitation of mix mulIers, flasks and cooling line. The simulation can be easily changed to simulate the production on other moulding machines and product categories too.

Three scenarios of suggested improvement approach are run on the simulation programs and the results of number of moulds produced are then recorded. From these simulation results, we calculate and compare the total yields of each approach. Conclusion and recommendation is then given based on this comparison, where each has each limitation.



Research location : PT Bakrie Tosanjaya

Supervisor: Ir. Antarikso Abulrahman, MBA.

Accepted: [November] 1993