LABORATORIUM SISTEM PRODUKSI DAN OTOMASI

FAKULTAS REKAYASA INDUSTRI

UNIVERSITAS TELKOM
Gedung Manufaktur, Jalan Telekomunikasi 1, Bandung, 40257

BAB I
PERENCANAAN PROSES DAN WAKTU BAKU

1.1. Product Description

1.1.1. Trolley

The product that used in 1st modul is trolley. Trolley is a tool that widely used for
moving heavy goods from first place to another place. The benefit from using trolley is
user can move heavy goods easily. Usually big company choose to use trolley for
maintain their human resources performance and make the job more efficient. The
specification:

Dimension Unit

: 105 X 105 X 900 MM

Capacity (kg)

: 150

Castor (inch)

: 3.5 PP + TPR

Length (L) (mm)

: 105

Width (W) (mm)

: 105

Height (H) (mm)

: 900

Net Weight (kg)

: 6.7

1.1.2. Component Product

The image below is the component product of trolley

Product

Picture

Specification

Name
M5 Bolt made
from stainless
steel, has
40mm length

M5 40mm

M5 Bolt made
from stainless
steel, has
20mm length

M5 20 mm

M6 Bolt made
from stainless
steel, has
50mm length

M6 50 mm

Product

Picture

Specification

Name
M4 Bolt made
from stainless
steel, has 3,4
mm length

M4 3,4
inch
Nut for M5
made

from

stainless steel

M5 Nut

Black M5
Bolt made
from stainless
steel, has
18mm length
M5 18mm

Nut for M6
made

from

stainless steel

M6 Nut

Product

Picture

Specification

Name
Big Spring
that made
from steel

Big Spring

Small Spring
that made
from steel

Small
Spring

Cover for
Small Spring
and Big
Spring, made
from
Spring
Cover

alumunium

Product

Picture

Specification

Name
Square tube
that made
from
alumunium,
Strengethen
Square

the holder

Tube

M5 Bolt made
from stainless
steel, has
25mm length

M5 25mm

Black-steel
gear
located

that
in

intersection of
chasis
Gear

and

handle

Back-chasis
made from
alumunium.

Chasis

Product

Picture

Specification

Name
2 black front
wheel

made

from stainless
steel for its
bracket

and

Front

rubber for the

Wheel

wheel tube
2 black front
rotatably
wheel

that

made

from

stainless steel
Rear

for its bracket

Wheel

and rubber for

the wheel tube
Lower body
Trolley with
black color
and made

Lower

from plastic

Body
Trolley
Upper

body

trollet

with

black

color

and

made

from plastic
Upper
Body
Trolley

Product

Picture

Specification

Name
Black handle
made
Handle

from

plastic

1.2. Standard Time Calculation

Work Station 1
SISPROMASI Trolley
Workstation 1
Operator Name : Eriko Mahtamtama
Timer Name : Nazahra Rizky Maghfira
Operation Name : Wheels Assembly
Produk keAssembled Component
Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
1
Wheel,Wheel Bracket,Wheel Bracket
0:00:00
0:02:40
0:02:40
160
2
wit Spinnning Lacquer,M6 Nut,M6
0:07:11
0:09:30
0:02:19
139
50mm Bolt
Cycle Time Average
150
Adjustment
0.13
Normal time
168.935
Allowance
0.377
Standart time
232.623495

Adjustment factor
Skill
Average
Effort
Good
Condition Good
Consistency Good
Total

0.03
0.05
0.02
0.03
0.13

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

6
1
0
4
22
0
0
33
2.2
2.5
37.7
0.377

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has quite good skill to fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis :
o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 82 . It means the
element product that produce need 82 second to move from work station one to
another work station . But the range of number too much, it does not good if

the amount of work station too much. We suggest to reduce the amount of
work station.

Work Station 2 :
SISPROMASI Trolley
Workstation 2
Operator Name : Muhammad Januar Rasyid
Timer Name : Wahid Aminullah
Operation Name : Gear Assembly
Product
1
2

Assembled Component
Gear,Chassis,M6 40mm,M6 Nut

Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
0:00:00
0:12:20
0:12:20
740
0:17:42
0:27:57
0:10:15
615
Cycle Time Average
Adjustment
Normal time
Allowance
Standart time

Adjustment factor
Skill
Good
Effort
Good
Condition Good
Consistency Good
Total

0.06
0.05
0.02
0.01
0.14

677.5
0.14
772.35
0.377
1063.52595

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

6
1
0
4
22
0
0
33
2.2
2.5
37.7
0.377

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has quite good skill to fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis :
o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 385.5. . It means the
element product that produce need 385.5 second to move from work station
one to another work station . But the range of number too much, it does not
good if the amount of work station too much. We suggest to reduce the amount
of work station.

Work Station 3
SISPROMASI Trolley
Workstation 3
Operator Name : Wirandy Saputra
Timer Name: Fadhilah
Operation Name : Assembly Chasis & Body
Product
Assembled Component
Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
1
M5 Nut, M4 3/4,M5 40mm bolt, M5
0:12:20
0:27:39
0:15:19
919
2
25mm bolt, M5 Nut, M6 Nut, M6
0:27:57
0:44:44
0:16:47
1002
50mm Bolt
Cycle Time Average
960.5
Adjustment
0.13
Normal time
1085.365
Allowance
0.402
Standart time
1521.68173

Adjustment factor
Skill
Good
Effort
Good
Condition Good
Consistency Good
Total

0.03
0.05
0.02
0.03
0.13

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

7.5
2
0
4
22
0
0
35.5
2.2
2.5
40.2
0.402

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has a good skill but the operator feel a little hard when fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis :
o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 560. It means the
element product that produce need 385.5 second to move from work station
one to another work station . But the range of number too much, it does not
good if the amount of work station too much. We suggest to reduce the
amount of work station.

Work Station 4

SISPROMASI Trolley
Workstation 4
Operator Name : Dhawy Farras Putra
Timer Name: Fauziyah
Operation Name : Assembly Spring with Body and Spring Cover
Product
1
2

Assembled Component
Big Spring, Small Spring,Spring
Cover,M5 25mm Bolt, M5 Nut, M3 3/4

Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
0:27:39
0:38:50
0:11:11
671
0:44:44
0:52:35
0:07:51
471
Cycle Time Average
Adjustment
Normal time
Allowance
Standart time

Adjustment factor
Skill
Good
Effort
Good
Condition Good
Consistency Good
Total

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

0.03
0.05
0.02
0.03
0.13

571
0.13
645.23
0.387
894.93401

6
2
0
4
22
0
0
34
2.2
2.5
38.7
0.387

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has quite good skill to fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis :
o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 323. It means the
element product that produce need 323 second to move from work station
one to another work station . But the range of number too much, it does not
good if the amount of work station too much. We suggest to reduce the
amount of work station.

Work Station 5

SISPROMASI Trolley
Workstation 5
Operator Name : Fikri Abdulhakim
Timer Name : Aprilia Ratna Aristamia
Operation Name : Assembly Square Tube Profile and Wheels
Product
Assembled Component
Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
1
0:38:50
0:47:06
0:08:16
496
M6 Nut, M6 40mm bolt,Square Tube
2
0:52:35
1:00:44
0:08:09
489
Profile
Cycle Time Average
Adjustment
Normal time
Allowance
Standart time

Adjustment factor
Skill
Average
Effort
Good
Condition Good
Consistency Good
Total

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

0.03
0.05
0.02
0.03
0.13

492.5
0.13
556.525
0.377
766.334925

6
1
0
4
22
0
0
33
2.2
2.5
37.7
0.377

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has quite good skill to fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis:

o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 274. It means the
element product that produce need 274 second to move from work station
one to another work station. But the range of number too much, it does not
good if the amount of work station too much. We suggest to reduce the
amount of work station.

Work Station 6

SISPROMASI Trolley
Workstation 6
Operator Name : Aryo Damarriyanto
Timer Name : Sarah Nurlaila
Operation Name : Assembly Handle and Lower Part
Product
1
2

Assembled Component
Handle, M5 Nut, M5 40mm bolt

Product Entry Time Product Out Time Product's Cycle Time Product's Cycle Time (Second)
0:47:06
0:50:11
0:03:05
185
1:00:44
1:05:58
0:05:14
314
Cycle Time Average
Adjustment
Normal time
Allowance
Standart time

Adjustment factor
Skill
Good 0.03
Effort Good 0.05
Condition Good 0.02
Consistency Good 0.03
Total
0.13

Allowance Factor
Energy
Work Posture
Work Movement
Eyes Exhaustion
Work Temperature
Atmosphere
Environment
Sub-Total
Personal Needs
Uncontrollable Constrain
Total Allowance

249.5
0.13
281.935
0.402
395.27287

7.5
2
0
4
22
0
0
35.5
2.2
2.5
40.2
0.402

Skill
Effort
Condition
Consistency

Analyze of Allowance Factor

The operator has quite good skill to fix the job
The operator has quite good effort to fix the job
The condition is good enough for operator to fix the job
The operator has well enough consistency when working

Analysis:
o If the number of adjustment getting smaller, so the number of cycle time will
become more small. Its mean the performance of worker is better.
o Standard time is affected by Normal time and allowance.
o Range number between cycle time and standard time is 146. It means the
element product that produce need 146 second to move from work station one
to another work station. But the range of number too much, it does not good if
the amount of work station too much. We suggest to reduce the amount of
work station.

1.3. Operation Process Chart

Analysis:

Sispromasi trolley assembly process consists of six elements of the work. Elements of
the work that requires the shortest time is the first work element that wheel and bracket
assembly, while the elements of work that requires the longest time is working elements
of body and chassis assembly. Assembly element of sispromasi trolley need time 3171
second.

1.4. Product Structure

The product structure diagram show about the constituent element of sispromasi trolley.
Which is mean:
o Level 0 is filled by Trolley
o Level 1 is filled by Handle, Upper Body, and Lower Body. It means that trolley is
divided by 3 big element ( Handle , Upper Body and Lower Body )
o Level 2 is filled by M3 12 mm , M5 20 mm , Spring Cover ,Big Spring , Small
Spring , M5 25 mm bolt , M5 Nut , M5 40 mm , M4 , Chassis , Gear , M6 Nut , M6
40 mm bolt , square tube , Front Wheel, and the last Rear Wheel.
o Level 3 is filled by element of rear Wheel ( Wheel , Wheel Bracket with spinning
Lacquer , M6 50 mm , M6 Nut ) and element of front wheel ( M6 50 mm , M6 Nut ,
Wheel , Wheel Bracket , M6 50 mm , M6 Nut )
The ordinate that listed under the element of product name means to explain about
Inventory, Lead Time, and Quantity. For example:
Trolley ( 0,0,1 ) mean Trolley with :
o 0 Inventory
o 0 Lead Time
o 1 Quantity

1.5. Bill of Material

Product

Level
0
0

1
2

Sispromasi

3
3
3
3
2
3
3
3
3

Trolley

2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1

Part Code

Name Part

Quantity

TRL001
TRL002
TRL003
TRL004
TRL005
TRL006
TRL007
TRL008
TRL009
TRL010
TRL011
TRL012
TRL013
TRL014
TRL015
TRL016
TRL017
TRL018
TRL019
TRL020
TRL021
TRL022
TRL023
TRL024
TRL025
TRL026
TRL027
TRL028

Sispromasi Trolley
Lower Body
Rear Wheel
Wheel
Wheel Bracket with spinning Lacquer
M6 50 mm
M6 Nut
Front wheel
Wheel
Wheel Bracket
M6 50 mm
M6 Nut
Square tube profile
M6 40 mm bolt
M6 Nut
Gear
Chasis
M4 3/4'
M5 40 mm
M5 Nut
M5 25 mm bolt
Small Spring
Big Spring
Spring Cover
M5 20mm
M3 12mm
Upper Body
Handle

1
1
1
2
2
2
2
2
2
2
2
2
2
8
8
2
1
4
2
2
4
2
2
2
2
6
1
1

Unit Lead Time

pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Number of
Operator
6
5
3
3
3
3
3
3
3
3
3
3
2
2
2
5
5
5
5
5
5
3
3
3
3
3
5
5

Workstation
1,2,3,4,5,6
2,3,4,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
1,5,6
5,6
5,6
5,6
2,3,4,5,6
2,3,4,5,6
2,3,4,5,6
2,3,4,5,6
2,3,4,5,6
2,3,4,5,6
4,5,6
4,5,6
4,5,6
4,5,6
4,5,6
2,3,4,5,6
2,3,4,5,6

Analysis:

Bill of Material is based on how product structure made. Bill of Material explain about series
of structures of all components used to manufacture the final product. So, we can know all
about manufacure activities. From Bill of Material above, there are the kind of product, the
level, part code, the name of part, quantity, unit, lead time, number of operator and
workstation. We can decide the level of bill of material after we make product structure. Bill
of Material support for MRP that will learn by the writers in the next practicum.