Right now, company XYZ often has trouble in production planning. Marketing Department people often complaint due to they have no stock to distribute to customers while in the same they are also required to achieve monthly target. Therefore, this research has been done to analyze several problems in the production process of Comapny XYZ. From the fishbone diagram, can be identified that there are several causes of the problems, namely indispline in making forecasts, production scheduling, production capacity, down time machine and arraving time of materials. Of the several causes have been carried out to the Pareto analysis to determine Pareto of potential problems.



To analyze the problem, some data collected from company XYZ, also had been conducted interviews with several employees at Company XYZ associated with the production process. The data collected is limited only for OTC products only, and in analyzing the accuracy of forecasts, taken two products which based on sales Pareto analysis has the largest sales.

Some of the analyses are as follows:

1. Measure quality of forecasting using time series moving average method to get the error-level value

2. Measure the sales data by quantity

3. Measure the qunatity production capacity

4. Measure the scheduling accuracy

5. Measure machine quality and capacity based on down time for each machine that used

6. Measure the material arrival whether on time or not by count the percentage of on time compare with late-time

7. Measure the involvement of human capacity to improve the capacity production

8. Measure the environment, in this project the measurement is by measure the landscape of production room.

From all the result and analysis can be drawn some conclusions that management must do immediately to improve the system and strategy that can return the balance of the system between factory with the marketing. The recommended system improvement in machine capacity, improvement in forecasting systems so it could be able to estimate the market demand, improvement in scheduling preventive maintenance, create the system of regulating and controlling the inventory of spare parts.

By considering all of those factors, can be known whether the plant is able to do the production according to market demand and sales forecasting or not. In ensuring appropriate plant capacity and sales forecasts, management systems need to adjust the factory or having preventive machine schedule along with the production schedule. Factory management will also have to periodically review the batch size of product production. Products with a little batch size that has to be produce often because of sales' forecasting higher should be enlarged in order to save time and ensure the production of stock products and equipment availability.





Research Location : PT XYZ



Confidential until 2015.