Bottleneck Analysis and Spreadsheet-Based Simulation for Enhancing Jersey Production Capacity at CV Wirakundara

Abstract

CV Wirakundara, a garment manufacturing company located in Sariwates, Bandung, faces uncertainty regarding its actual jersey production capacity and the utilization levels of operators in its sewing line. This study aims to (1) identify the actual process capacity of jersey production and determine its bottleneck point, and (2) measure the average performance and utilization of each operator. The study employs the Bottleneck Analysis method to address the first objective and Spreadsheet-Based Computer Simulation to address the second objective. The results of the bottleneck analysis indicate that the overlocking process, with a processing time of 5 minutes, is the most critical bottleneck in the production line. By adding one operator and one overlocking machine, the cycle time can be reduced to 2.5 minutes, thereby increasing production capacity from approximately 96 pieces per day to 192 pieces per day.  The simulation results reveal that the utilization rates of Operator A and Operator B are 86.95% and 78.29%, respectively, with average waiting times of 21 seconds and 36 seconds. This study proposes several improvement recommendations, including enhancing the overlocking process, providing intermediate storage areas between production stages, and conducting further evaluation and training for operators to improve production capacity at CV Wirakundara