Design of disturbances control model at automotive company

The discussion was conducted at PT. XYZ which produces automotive components and motorcycle products. The company produced X123 type cylinder head which is a motor vehicle forming component. The disturbances in the production system has affected the company performance in achieving the target of Key Performance Indicator (KPI). Currently, the determination of the percentage of safety stock of cylinder head products is not in accordance to the control limits set by the company (60% - 80%), and tends to exceed the control limits that cause increasing the inventory wastage in the company. This study aims to identify the production system disturbances that occurs in the production process of manufacturing components of X123 type cylinder head products and design the control model of disturbance to obtain control action and determine the safety stock policy in accordance with the needs of the company. The design stage has been done based on the Disturbance Control Model which already existing and customized with the company need in controlling the production system disturbances at the company. The design of the disturbances control model consists of sub-model of the risk level of the disturbance, sub-model of action status, sub-model action control of the disturbance, and sub-model of determining the safety stock. The model can assist the automotive company in taking the decision to perform the disturbances control action in production system cylinder head while controlling the percentage of the safety stock. (paper)