SIMULATION MODELLING TO IMPROVE THE PRODUCTION CAPACITY OF THE PLASTIC INJECTION LINE AT PT XYZ USING PLANT SIMULATION SOFTWARE: A CASE STUDY

Abstract

PT XYZ faces production capacity limitations of 2,250 part-sets per day of plastic parts, with an additional 400 part-sets demand that drives 40.5% overtime costs. This study develops a simulation model to improve the K-XX injection line. Using the DMAIC (Define, Measure, Analyze, Improve, Control) framework. By combining real data collection, FGD (Focus Group Discussion), OEE (Overall Equipment Effectiveness), Six Big Losses Analysis and simulation using Tecnomatix Plant Simulation, aiming to address inefficiencies in cycle time and machine downtime and quality issue. The modelling output indicates an 8.89 % increase in capacity, from 2,250 to 2,450 part-sets per day. The OEE improves from 78.0 % to 85.3 %, surpassing company targets and approaching world‑class standards. Cost analysis reveals a 43.5 % reduction in annual overtime for the K‑XX injection line, showing improved capacity utilisation, balanced scheduling, and more efficient labour control. Forecast accuracy remains high, with MAPE (Mean Absolute Percentage Error) 1.69 %. These findings demonstrate that simulation modelling supports informed decision-making in sustainable production planning and control.