12/02/2018

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Managing WIP buffer with combination of

feeding materials scenario and conventional
control theory of single type of hospital bed
production

by : Susanto Sudiro & Shar’i Mohd Yusof

PT Mega Andalan Kalasan and Mechanical Engineering
Departement University Pancasila
UTM RAZAK School of Engineering and Advanced Technology

Problem Identification
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Sales, Production, Stock and Delivery

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Product
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Product
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Welding and Assembly Plant

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Multi Buffer Multi Machine System

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Day-1(day minus one) WIP Buffer scenario in

the Assembly Plant for Single Bench
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Timing scheme of buffering WIP using

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method D minus 1

COMPANY PROFILE , MEGA ANDALAN KALASAN, pt. 2/12/2018

Open Loop Mathematical Equation 1

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Open Loop Mathematical Equation 2

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Is supply of finish weld to buffer B2

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Case Study
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 Products J0014MSR8E TRG 23 Bed

 Shipment Ordery, 1 containers , quantity 134 units every week
 Cycle Time and Line Balancing:

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D minus 1 of Assembly, Painting and Welding

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Display control responds of close loop production system

for produce 134 units bed for shipping time 5 days
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Conclusion 1
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This study has attempted to develop a new

method for manage WIP buffer. The following
results have been achieved and presented in
this paper:
a) A method to manage WIP Buffer use D
minus 1, with the” Day 0” being time
scheduled to assembly the finish goods.
Day minus 1 is day schedulled on the
upstream buffer WIP materials supply .

COMPANY PROFILE , MEGA ANDALAN KALASAN, pt. 2/12/2018

Conclusion 2
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b) An application program for simulation of this design

scenario based on conventional control theory has
been developed using MATLAB. The application can
be used to make a D Minus 1 production plan
scenario and diagnose the stability of production
process .
c) The method in a) and b) has been applied for
shipment containers number 41 to 45. The
production scheduled was implemented in the
production floor and was able to achieve delivery on
time as scheduled. Controller parameter to control
stability of process is use time constant<=1 and
proportional gain=1.
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Future Work
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 Future work will involve production planning

and scheduling to manage WIP buffer of
production multi product hospital bed and
completing the simulation program to
respons of disturbance on production
process.

COMPANY PROFILE , MEGA ANDALAN KALASAN, pt. 2/12/2018

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 Thankyou

COMPANY PROFILE , MEGA ANDALAN KALASAN, pt. 2/12/2018