Abelia Dhuwi Juwita (1), Enny Aryanny (2)
General Background: Manufacturing productivity requires well-distributed workloads, minimized idle time, and efficient workstation allocation. Specific Background: PT XYZ, a Surabaya manufacturing company producing single fire doors, experienced workload imbalance, work-in-process accumulation, and bottlenecks at the welding workstation. Knowledge Gap: Previous line balancing studies had discussed RPW and Region Approach methods, but limited integration was found between these methods, root-cause analysis through fishbone diagrams, ergonomic considerations, and the technical sequence of single fire door operations. Aims: This study aimed to determine the optimal balancing arrangement for the single fire door production process to improve operational efficiency at PT XYZ. Results: Using a quantitative case-study approach, cycle time, normal time, and standard time were analyzed for 12 work elements observed directly with a stopwatch. The actual condition with four workstations showed 61.90% efficiency, 38.10% Balance Delay, and a Smoothing Index of 148.63 minutes. After optimization using Ranked Positional Weight and Region Approach methods, both methods produced five proposed workstations, increasing efficiency to 97.32%, reducing Balance Delay to 2.68%, lowering the Smoothing Index to 6.26, and reducing idle time from 252.13 to 11.27 minutes. Novelty: This study combines RPW, Region Approach, precedence-based work allocation, fishbone analysis, and ergonomic considerations for single fire door manufacturing. Implications: PT XYZ should standardize work instructions based on the new precedence diagram and apply periodic job rotation for physically demanding stations.
Highlights:
Keywords: Bottleneck, Ranked Positional Weight, Region Approach., Line Balancing.
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