Integration of Ergo-Manufacturing and Simulation to Minimise Waiting Time for Cracker and Kemplang Production Process Flow

Background. Belimo Food Industry factory is engaged in the production of crackers and kemplang with the Belimo brand. Observations made at the packing workstation indicate that there is still a buildup or bottleneck in the press machine that is not optimal, resulting in inefficient performance that violates many ergonomic principles in the manufacturing industry (Ergo-Manufacturing). Aims. This research explores the integration of Ergo-Manufacturing concepts with simulation. The study aims to improve performance and reduce process lead time. Methods. The research method employed is quantitative-descriptive, utilizing primary data. Data processing utilizes the integration method of the Ergo-Manufacturing concept with Arena software-based simulation to provide solutions that optimize process waiting time, improve efficiency, work comfort, and production capacity at the packing workstation. Result. The results of the study, after applying Ergo-Manufacturing with work environment settings, can minimize the waiting time of the initial condition process, with a process time of 58.273 minutes. Under the conditions of improvement scenario 1, the process waiting time of 26,830 minutes can reduce the process time by 60%, under the conditions of improvement scenario 2, the process waiting time of 14,562 minutes can reduce the process waiting time by 80% and under the conditions of improvement scenario 3, the process waiting time of 12,483 minutes can reduce the process time by 85%. Conclusion. The results of the BEP decision analysis for scenario one were selected by adding one press machine to 2 press machines, which can increase production capacity by 128 products. This also reduces overtime costs incurred by the company by 1.5 hours, amounting to IDR 40,500. The BEP investment in press machines takes 3 years.