Consumer Product Repetitive Production Planning with Color Sequence Wheel to Reduce Total Changeover Time

Abstract

In manufacturing, every minute a process is stopped to carry out changeover is one less minute of productive time. Therefore, reducing changeover time is a golden opportunity to unlock more productive time. Changeover time reduction increases operational efficiency for production and reduces waste. This research aims to improve production planning by applying the sequence wheel method to repetitive production. The focus is to find a new pattern by writing an algorithm in Visual Basic for Applications (VBA) on Microsoft Excel and propose a standard changeover color sequence wheel. In the analysis, two production conditions were set. First, loading process time was calculation only for the first job, loading times of the following processes were omitted. Second, the mixing process time was not included if two consecutive jobs with the same color were produced. This process consisted of eight jobs, and each work had eight steps. The analysis results found that a new pattern with two proposed conditions could reduce total changeover time by 22.22 percent, and the sequence should start from light to dark color with package sizes consideration.