Shop floor control improvement for a music instrument factory

Abstract

The objective of this research is to study and develop shop floor control system for the music instrument company in the case study. Find out the solution in production plan and assignment job clearly based on process to minimize all problems in the Conga Drum production line. There are three main problems which are organisation management and relationship, production, expenses and due date. The research was started from defining clearly to the causes of the problems by collecting necessary data. Improvement process is starting from reorganization, production improvement, and relay out. The solutions is to applied theory, concepts and tools that related to shop floor control such as divide and assign job clearly, follow up tools, built-in quality concept. The results illustrate that company can set due date more accurate and reduce lateness due date from 90 days to 30 days. Defects reduce by 2-10%, therefore productivity per worker increase around 5-20%. The production cost in term of electricity used reduces from 10,000 units to 9,000 units.