Combining Drum-Buffer-Rope Algorithm and Kansei Engineering to Control Capacity Constrained Worker in a Bioproduction System

Worker capacity is influenced by various factors of standard time, physical, mood and environment. The Capacity Constrained Worker (CCW) can be described as a worker capacity is close or equal with incoming material so that the fluctuation of incoming material flows possible to shift the CCW into a bottleneck condition of process. Recognizing CCW and bottleneck is essential to maintain the planned product flow in each work station. The objective of the research is to identify and control CCW and bottleneck. The case study of this research is in half-fermented ‘Tempe’ industry. CCW and bottleneck were identified using 4 parameters of standard time, profile of mood status, heart rate and environmental condition. The research results indicated that the CCW was identified on worker of peeling station while bottleneck was identified on the worker of threshing station. The arrival rate of each station inside the Bioproduction system was balanced using the lowest service rate. A buffer time is derived by deviation between service rate of worker in CCW and bottleneck and balanced arrival rate using Drum-Buffer-Rope algorithm. Buffer time was added before threshing and peeling station.