Departemen Teknik Industri FTI-ITB

TI-3122 Perencanaan dan Pengendalian Produksi Perencanaan Tenaga Kerja

Laboratorium Sistem Produksi www.lspitb.org 2003

Departemen Teknik Industri FTI-ITB

Hasil Pembelajaran

Umum
Mahasiswa mampu menerapkan model matematik, heuristik dan teknik statistik untuk menganalisis dan merancang suatu sistem perencanaan dan pengendalian produksi

Khusus
Mampu menghitung kebutuhan tenaga kerja

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Departemen Teknik Industri FTI-ITB

INTRODUCTION (Production Planning System)

Aggregate Planning Master Production Schedule Material Requirements Planning Planned Order Release/Scheduling

Production scheduling

staffing facility with people

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Departemen Teknik Industri FTI-ITB

INTRODUCTION (Characteristics)

Characteristics:
Demand tends to fluctuate widely in the short term and to occur seven days a week Human effort cannot be inventoried Customer convenience is critical

Steps to solve the problem:

Identify the services to be provided Determine the average time required for each service Forecast the demand for each service over the seven day period and for the staffs Smooth out the staffing needs

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Departemen Teknik Industri FTI-ITB

INTRODUCTION (Definition)

Demand: the number of people needed during some

periods to provide a predefined level of service. A weekly demand forecast is the number of people to be employed during each day of the week

Shift:
(1) the time of a day when a person begins work and takes a rest and breaks during the day. Example: Shift 5 starts at 08:00 with 15 minutes off at 10:00 and 14:00, and lunch from 12:15 to 12:45 (2) the set of days during a given week when a person will be expected at work. Example: Shift 5 is Monday through Friday, with Saturday and Sunday off

Schedule: the set of shifts that satisfies the demand criteria

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Departemen Teknik Industri FTI-ITB

SHIFT SCHEDULING
Objective: to provide an adequate number of people at
minimum labor cost

A total of 28 people-days Since each individual works 5 days, it requires 6 shifts (6

people) Figure 1 shows a very simple daily demand forecast and shift schedule The solution contains overstaffing on Tuesday and Friday. It contains only 2 Saturday/Monday off shifts but everyone at least has consecutive days off The solution is optimal in that it requires six people (the minimum feasible)

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Departemen Teknik Industri FTI-ITB

Sun

Mo n

Tue

We Thu d #1 Shift
Shift #2 Shift #3 Shift #4

Fri

Sat

Shift #5 Shift #6 Staff Demand Overstaff 2 2 0 4 4 0 5 4 1 5 5 0 5 5 0 5 4 1 4 4 0 Sum 30 28 2

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Departemen Teknik Industri FTI-ITB

ALGORITHMS Tibrewala, Philippe, and Browne

Step 1: Working from the largest manpower-need

day to the second largest and so forth, do the following. Place all days with the same manpower need on the schedule until a unique twoconsecutive-days off period appears. If a tie exists, go to Step 2. Step 2: If two identical two-days-off periods occur, select the pair with the smallest requirements on adjacent days. If the tie cannot be broken, go to Step 3. Step 3: Select the most reasonable pair; for example, the one that has a Saturday/Sunday off or the first pair in the week
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Departemen Teknik Industri FTI-ITB

Sun 4 0 4 0 4 -1 3 -1 2 0 2

Mon 8 -1 7 -1 6 -1 5 -1 4 -1 3

Tue 7 -1 6 -1 5 0 5 -1 4 -1 3

Wed 7 -1 6 -1 5 0 5 -1 4 -1 3

Thu 7 -1 6 -1 5 -1 4 0 4 -1 3

Fri 7 -1 6 -1 5 -1 4 0 4 -1 3

Sat 6 0 6 0 6 -1 5 -1 4 0 4 #5 #4 #3 #2 Init.dem #1

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Departemen Teknik Industri FTI-ITB

2 0

3 0

3 -1

3 -1

3 -1

3 -1

4 -1 #6

2
-1

3
-1

2
0

2
0

2
-1

2
-1

3
-1 #7

1
-1 0 0 0 0 0

2
-1 1 -1 0 0 0

2
-1 1 -1 0 -1 1

2
-1 1 -1 0 -1 1

1
0 1 -1 0 -1 1

1
0 1 -1 0 -1 1

2
-1 1 0 1 -1 0 #10 #9 #8

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Departemen Teknik Industri FTI-ITB

Demand Total: 46

Requirement: 45/6 = 9.2 ~ 10 people, 4 overstaff

Solution

4 shifts with Saturday/Sunday off

2 shifts with Sunday/Monday off

2 shifts with Tuesday/Wednesday off

2 shifts with Thursday/Friday off

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Departemen Teknik Industri FTI-ITB

ALGORITHMS Monroe

Step 1. For each day of the week, calculate the

regular days off (RDOs) by subtracting the daily staff need from the chosen staff size. The summed staff need must be an even multiple of 5 if five-day work weeks are to be scheduled. If this is not the case, add to the staff needs of one or more days until a multiple of five is reached.

Step2. Beginning with the first two days of the

week, establish pairs of RDOs until the first pair is repeated second time.
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Step 3. For a first trial at scheduling pairs of RDO, assign

ALGORITHMS Monroe

approximately half of the second days RDO to the first pair of days off. Subtracting this assignment from the second days RDO, assign the reminder to the second pair of days off. Continue this procedure until all pairs have assignments. If the first and second occurrences of the first pair are equal, stop; otherwise go to Step 4.

Step 4. Calculate the average of the assignment to the first

and second occurrences of the first pair of days off. Use this as the second trial assignment for the first pair. Using this procedure in Step 3, reassign all pairs of days off.

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE (Example)

Demand: 46 people-days To make the demand a multiple of 5, there are two alternatives: 46 45 or 46 50 If the chosen alternative is to adjust the demand to be 50, Minimum required staff : 50/5=10, meaning that there are 4 extra (dummy) demand allocated to Tuesday, Wednesday, Thursday and Friday

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE (Example)

Sun Mo 8 8 Tue 7 8 We 7 8 Thu 7 8 Fri 7 8 Sat 6 6

Initial demand Adjusted

4 4

Minimum staff Forecasted demand

10 4

10 8

10 8

10 8

10 8

10 8

10 6

Reg.day off (RDO)

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE (Example)

Mo 2 S/ M 1 2 Solution: Tu 2 M/ T 1 0 We 2 T/ W 1 2 Th 2 W/ T 1 0 Fr 2 T/ F 1 2 Sa 4 F/ S 1 0 Su (6) S/ S 3 4 Mon (2)

Su RDOs 6

Dayoff pairs First trial Second trial

S/M
(3) (2)

2 S/M off schedules

2 T/W off schedules

2 T/F off schedules 4 S/S off schedules 16

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Departemen Teknik Industri FTI-ITB

Mabert and Raedelss Method

Part time worker need

Sun Mo Tue We Thu Fri Sat

Total need Full time Part time

0 0 0

11 5 6

6 5 1

8 5 3

6 5 1

10 5 5

0 0 0

Worker ID number: 1, 2, 3, 4, 5 and 6 The lower ID number the greater seniority Seniority people desire to work maximum hour

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Departemen Teknik Industri FTI-ITB

Mabert and Raedelss Method

The resulting schedule Monday Tuesday Wednesday Thursday Friday 1, 2, 3, 4, 5, 6 1 2, 3, 4, 5 6, 1, 2, 3, 4

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Departemen Teknik Industri FTI-ITB

Linear Programming Model (Monroes Algorithm)

b1= required RDO for Mon b2= required RDO for Tue b3= required RDO for Wed b4= required RDO for Thu b5= required RDO for Fri b6= required RDO for Sat b7= required RDO for Sun

Definitions (Rothstein)
x1= number of Sun/Mon RDO pairs; x2= number of Mon/Tue RDO pairs; x3= number of Tue/Wed RDO pairs; x4= number of Wed/Thu RDO pairs; x5= number of Thu/Fri RDO pairs; x6= number of Fri/Sat RDO pairs; x7= number of Sat/Sun RDO pairs;

u1= number of Mon in non consecutive RDOs u2= number of Tue in non consecutive RDOs u3= number of Wed in non consecutive RDOs u4= number of Thu in non consecutive RDOs u5= number of Fri in non consecutive RDOs u6= number of Sat in non consecutive RDOs u7= number of Sun in non consecutive RDOs d = number of workers who will be assigned non consecutive RDOs

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Departemen Teknik Industri FTI-ITB

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