Analysis of Production Planning of Cocoa Products Using Workload Analysis and Operation Scheduling

Industrial Engineering Department, Faculty of Engineering, Bina Nusantara University, Jakarta 11480, Indonesia

^* Corresponding author: hhchie@binus.ac.id

Abstract

The fluctuating demand levels each period is a significant challenge in the company’s production. Production scheduling stands out as a crucial process in the production system. PT XYZ, a privately-owned company specializing in cocoa plantations in Indonesia, faced problem in production planning, leading to delays in chocolate product output. This study delved into the workload experienced by the production operator and the production schedule using the workload analysis and the Campbell Dudek Smith (CDS). Data were collected through observations and interviews. The results revealed that the total workload for the current eight production operators in each production room was 988.1%. The existing production schedule was not optimal as indicated with an excessively high makespan of 170. Implementing the CDS method reduced the makespan to 151, enhancing performance by 19% and saving 12% of time. The findings suggest that introducing two additional workers could alleviate the overall workload for production operators. In addition, the proposed production schedule prioritizes chocolate powder, followed by chocolate butter, chocolate liquid, and chocolate bars. The implications of this research extend to potential benefits for the company, including improved work quality, enhanced production efficiency, and an overall enhancement of the company’s performance.