Analisis Production Activity Control (PAC) pada Proses Produksi Ragum Menggunakan Algoritma Hodgson di PT XYZ

Abstract

Keterlambatan produksi pada industri manufaktur dapat menurunkan efisiensi operasional dan meningkatkan biaya penalti, sehingga diperlukan Production Activity Control (PAC) yang efektif. Penelitian ini bertujuan menganalisis penerapan PAC pada proses produksi ragum di PT XYZ menggunakan algoritma Hodgson untuk meminimasi keterlambatan produksi dan mengevaluasi kesesuaian antara perencanaan dan realisasi produksi. Data yang digunakan meliputi routing file, planned order release hasil Material Requirement Planning (MRP), dan data hari kerja produksi. Analisis dilakukan melalui perhitungan starting time, waktu proses, due date, penjadwalan menggunakan algoritma Hodgson, serta evaluasi dispatching, expediting, dan production reporting. Selain itu, dilakukan analisis bottleneck dan identifikasi penyebab keterlambatan aktual. Hasil penelitian menunjukkan bahwa secara teoritis algoritma Hodgson menghasilkan jadwal tanpa tardy jobs dengan nilai lateness negatif pada seluruh periode analisis. Namun, implementasi aktual masih mengalami keterlambatan akibat ketidakseimbangan beban kerja, kompleksitas routing, dan keterbatasan pengendalian operasional, yang menyebabkan biaya penalti sebesar Rp307.500.000. Penelitian ini menunjukkan bahwa efektivitas PAC tidak hanya dipengaruhi oleh metode penjadwalan, tetapi juga oleh kemampuan monitoring produksi dan pengendalian operasional secara real-time.

Production delays in manufacturing industries can reduce operational efficiency and increase penalty costs, thereby requiring effective Production Activity Control (PAC). This study aims to analyze the implementation of PAC in vise production at PT XYZ using the Hodgson algorithm to minimize production delays and evaluate the conformity between production planning and actual implementation. The data used include routing files, planned order release generated from Material Requirement Planning (MRP), and production working-day data. The analysis was conducted through the calculation of starting time, processing time, due date, scheduling using the Hodgson algorithm, and evaluation of dispatching, expediting, and production reporting. In addition, bottleneck analysis and identification of actual delay causes were carried out to strengthen the production performance evaluation. The results show that theoretically the Hodgson algorithm produces a schedule without tardy jobs, indicated by negative lateness values in all analysis periods. However, actual implementation still experienced delays due to workload imbalance, routing complexity, and limitations in operational control, resulting in penalty costs of Rp307,500,000. This study indicates that PAC effectiveness is influenced not only by scheduling methods but also by production monitoring capability and real-time operational control.