Analisis perencanaan kapasitas produksi departemen final quality dan packing menggunakan metode rough cut capacity planning (RCCP) di PT fastener

Abstract

This study aims to analyze and address production capacity imbalance between the Final Quality (FQ) and Packing departments at PT Fastener using an integrated Rough Cut Capacity Planning (RCCP) approach. The main issue faced by the company is the high level of Work in Process (WIP) caused by unsynchronized material flow, resulting in increased waiting time, reduced operational efficiency, and delayed product delivery. This research applies a mixed methods approach with an explanatory sequential design, combining quantitative and qualitative analyses.The baseline analysis reveals that the Packing department has a higher utilization rate than the FQ department, making it a bottleneck in the production system. This condition leads to significant WIP accumulation. To solve this problem, an integrated RCCP model is developed by combining Capacity Planning Using Overall Factors (CPOF) and Resource Profile methods. The model is supported by an integrated Bill of Resources (BOR) and incorporates lead time offset parameters, along with a capacity leveling algorithm to balance workloads between departments.Simulation results indicate that the implementation of the integrated RCCP model significantly reduces capacity imbalance, decreases WIP by 35–40%, and improves throughput time by 25–30%. Additionally, throughput rate and resource utilization are improved. Statistical testing confirms that the performance differences before and after implementation are significant.In conclusion, the integrated RCCP approach is effective in improving production system efficiency and can be applied as a practical solution for capacity management in manufacturing industries