PROCESS SIMULATOR FOR MANUAL HANDLING PESTICIDE PACKAGING ASSEMBLY LINE

Reducing production costs without sacrificing product quality is essential for the global market survival. The problem of line balancing, especially assembly line balancing, plays an important role for industry in achieving the highest quality and lowest cost. This project presents the simulation of line balancing the pesticide packaging assembly line in pesticidebased company. This study aims to develop a productive and effective way of assembling the product to meet customer demands. Line balancing is about arranging a production line so that the production flow from one workstation to the next is even. Line balancing also provides a successful tool to reduce bottleneck by balancing the task time of each workstation so that no delays occur, and nobody is overburdened with their work. The whole project contains study of line balancing through theoretical calculation and analysis done in the simulation model. The simulation was performed using the Process Simulator. Process simulator has been used to simulate the layout condition based in precedence diagram. The first step in using Process Simulator is to create a simulation model of a process in the Visio layout. This is accomplished by adding activities, entities, and resources to the Visio layout and then connecting them with arrival and routing connections. Overall simulation result shows that total unit produce for 5 weeks is 12,240 cartons with average time in system 11,293.85 minutes and average time in operation is 2.39 mins. Filling process and manual labelling process shows highest operation percentage. The percentage of blocked items increased before the bottleneck process. The assembly line plays a critical role in enabling the factory to deliver the right quantity and quality on time.