Optimizing Workforce Utilization in Motorcycle Component Assembly Using Simulation

Abstract

The lack of resource utilization has resulted in manufacturing staying at the same level for a long time. This problem cannot be solved simply by adding machines and hiring more labor. There is an urgent need for innovation and more investment in the development of manufacturing systems. Therefore, a strategic approach is needed to plan and handle the motorcycle component assembly process. This research aimed to evaluate the current workforce utilization of motorcycle parts assembly line, and put forward a feasible plan for the assembly company to achieve their best production based on limited workforce resources. The study specifically targeted assemblers located in Port Klang, Selangor. The data used for the research is the auxiliary data in a three-month time span and is recorded in the assembly company. Simulation is applied in this research to grasp the current situation and Arena simulation software tool is used. The improvement models are proposed by reallocating the workers into their designated workstations. The findings found that by setting a group of workers that operate in a cyclical manner assisted the assembler to maximize the workforce utilization rate. In order to make future research completer and more thorough, more exploration is encouraged by adding related measures (such as applied inventory practices, production and other related costs, and larger sample sizes). The results from this study can help the assembler management to make better decisions thus upgrading the motorcycle component assembly system.