THE IMPLEMENTATION OF SMART FACTORY ON

PACKOUT AREA USING ADDIE METHODOLOGY

AT TOY MANUFACTURING COMPANY

UNDERGRADUATE FINAL PROJECT

Submitted as one of the requirements to obtain Sarjana Teknik (S.T.)

By
Muhammad Afra Irwansyah
ID No. 004202000067

FACULTY OF ENGINEERING
INDUSTRIAL ENGINEERING STUDY PROGRAM
CIKARANG
MAY, 2023
 PANEL EXAMINER APPROVAL

The Panel of Examiners declare that the undergraduate final project

entitled “The Implementation of Smart Factory on Packout Area
Using ADDIE Methodology at Toy Manufacturing Company” that
was submitted by Muhammad Afra Irwansyah majoring in Industrial
Engineering from the Faculty of Engineering was assessed and
approved to have passed the Oral Examination on (mm/dd/yyyy).

Panel of Examiner

…………………………………………..
Chair of Panel Examiner

…………………………………………..
Examiner 1

ii
 FINAL PROJECT ADVISOR
RECOMMENDATION LETTER

This final project entitled “The Implementation of Smart Factory

on Packout Area Using ADDIE Methodology at Toy
Manufacturing Company” prepared and submitted by Muhammad
Afra Irwansyah in partial fulfillment of the requirements for the
degree of Bachelor Degree in the Faculty of Engineering has been
reviewed and found to have satisfied the requirements for a thesis fit
to be examined. I therefore recommend this thesis for Oral Defense.

Cikarang, Indonesia, May 19th, 2023

Anastasia Lidya Maukar, S.T, M.Sc, M.MT

iii
 STATEMENT OF ORIGINALITY

In my capacity as an active student of President University and as the author of

the thesis/final project/business plan stated below:

Name : Muhammad Afra Irwansyah

Student ID Number : 004202000067
Study Program : Industrial Engineering
Faculty : Faculty of Engineering

I hereby declare that my thesis/final project/business plan entitled "The

Development and Implementation of Smart Factory on Packout Area Using
ADDIE Methodology at Toy Manufacturing Company” is to the best of my
knowledge and belief, an original piece of work based on sound academic
principles. If there is any plagiarism detected in this thesis/final project/business
plan, I am willing to be personally responsible for the consequences of these acts
of plagiarism, and will accept the sanctions against these acts in accordance with
the rules and policies of President University.

I also declare that this work, either in whole or in part, has not been submitted to
another university to obtain a degree.

Cikarang, May, 19th, 2023

Muhammad Afra Irwansyah

iv
 SCIENTIFIC PUBLICATION APPROVAL FOR
ACADEMIC INTEREST

As an academic community member of the President’s University, I, the

undersigned:

Name : Muhammad Afra Irwansyah

Student ID Number : 004202000067
Study Program : Industrial Engineering

for the purpose of development of science and technology, certify, and approve to
give President University a non-exclusive royalty-free right upon my final report
with the title:

The Implementation of Smart Factory on Packout Area Using ADDIE

Methodology at Toy Manufacturing Company

With this non-exclusive royalty-free right, President University is entitled to

converse, to convert, to manage in a database, to maintain, and to publish my final
report. There are to be done with the obligation from President University to
mention my name as the copyright owner of my final report.

This statement I made in truth.

Cikarang, May, 19th, 2023

Muhammad Afra Irwansyah

v
 ADVISOR APPROVAL FOR
JOURNAL/INSTITUTION’S REPOSITORY

As an academic community member of the President’s University, I, the

undersigned:

Name : Muhammad Afra Irwansyah

Student ID Number : 004202000067
Study Program : Industrial Engineering
Faculty : Faculty of Engineering

declare that following thesis:

Title of thesis : The Implementation of Smart Factory on Packout

Area Using ADDIE Methodology at Toy
Manufacturing Company
Thesis author : Muhammad Afra Irwansyah
Student ID number : 004202000067

will be published in jornal/institution’s repository

Cikarang, May, 19th, 2023

Anastasia Lidya Maukar, S.T, M.Sc, M.MT

vi
THE IMPLEMENTATION OF SMART FACTORY ON
PACKOUT AREA THROUGH ADDIE
METHODOLOGY AT TOY MANUFACTURING
COMPANY

By
Muhammad Afra Irwansyah

Approved by

Anastasia Lidya Maukar, S.T, M.Sc, M.MT

Final Project Advisor

Ir. Andira Taslim, M.T

Study Program Head of Industrial Engineering

vii
SIMILARITY CHECKING RESULT

viii
AI BASED PLAGIARISM CHECKING RESULT

ix
ABSTRACT

x
 ACKNOWLEDGEMENT

This acknowledgement is presented to raise the praise of the people who has been
directly or indirectly support this research.
1. Gratitude to Allah SWT who has given me the opportunity and strength to
carry out this research and complete the report.
2. My beloved self as the bigest motivation to keep on progress to finish this
research and report.
3. My beloved family who always encourage me to put the best efforts on my
responsibilities.
4. Mrs. Anastasia Lidya Maukar, S.T, M.Sc, M.MT as my lecturer who
became my final project advisor that has been supporting me a lot in this
research and report.
5. Christopher for your amazing music.
6. My company’s supervisor.
7. All industrial engineering lecturer who has been giving me a lot of
knowledge.
8. All of my friends.
9. Others.

Sincerely,
Muhammad Afra Irwansyah

xi
TABLE OF CONTENTS

xii
LIST OF TABLES

xiii
LIST OF FIGURES

xiv
 LIST OF TERMINOLOGIES

IIoT : Industrial Internet of Things

WIP : Work-in-Process
ISD : Instructional System Design
ADDIE : Analysis, Design, Development, Implementation,
and Evaluation

xv
 CHAPTER I
INTRODUCTION

1.1 Background

Toy manufacturing company is type of company that produce large number of

products and its products’ variety. In accordance with that conditions, toy
manufacturing company is facing the challenges when it comes to its production
efficiency and waste elimination. There are many methodologies and approaches
to overcome the challenges to improve the production efficiency and waste
elimination.

PT TMC as one of the largest toy manufacturing company in the world also facing
the same challenges on its manufacturing system. In packout process as their
secondary process, work-in-process (WIP) parts are being assembled into one
packaged and finished product. The area of secondary production floor nearly to
10,672 m2 with length 115 meters and width 92.8 meters. This area consists of 124
active lines and 514 machines used to support the line. As the ambition of PT
TMC to become a world-class manufacturing company that optimize the
efficiency, many observations performed in order to determine the waste and
improve the efficiency.

As mentioned in advance, PT TMC as one of toy manufacturing company, also

facing the large number of products and its products’ variety. This condition leads
to the variety of secondary process. Secondary process adapted product layout
where the products being assembled in conveyor line. As the product variety, this
product layout also being changed based on the toy number. This activity called
layout changeover. Layout changeover is the activity performed to change the
tools, machines, and sequences in order to support the production. Based on
layout changeover report, there were 10,500 times of layout changeover on 2022.
While one layout changeover can take 15 minutes on average, 5 minutes for
simple layout changeover, and 20 minutes for complex layout changeover.
Workflow of layout changeover was being reviewed and analyzed in order to

1
understand the workflow and also analyze the shortcomings. The workflow was
determined as unefficient as the processes takes a lot of time due to the
information collection that are available on many sources such as layout
changeover summary, layout drawing, and detail of machine used are still using
paper or printed out and also for the machine location is unavailable.

As the ambition to optimize the efficiency of the production floor, machine

downtime is also one of the problem that needs to be fixed. As known that
machine downtime potentially reduce the number of output, especially for
manufacturing that applies product layout. So, it is clear that the machine
downtime needs to be reduced so the machine availability will be increased.
Machine downtime also related to the response time of the mechanic to be
available to repair the problem of the machine. Based on machine problem
reports, there were 6,294 machines downtime on 2022 with the average of 15.92
minutes of repair time. On the other side, response time is uncounted since current
system only depend on andon light. Also for the coverage area of mechanic that is
10,672 m2, it leads to the higher response time. There were many complaints
about the time needed for the mechanic to realize there is machine breakdown.
With the average of 15 minutes, even it can take 1 hours for only response time,
this condition become the shortcoming of packout area. It leads to the output that
is less than target.

Based on the explanation, it is important to develop a new system that can support
layout changeover process and machine repairment process. The first objective of
the improvement of layout changeover is to reduce the time needed to conduct
layout changeover. Meanwhile, the second objective of machine repairment
activity is to reduce the response time of the mechanics. The implementation of
smart factory become the great solution to overcome and achieve those objectives.
So, the objective of this research is to implement smart factory on packout area.
Smart factory can be defined as a relation of workers and machinery on the job
execution (Hozdic, 2015). By implementing smart factory, the objectives will be
achieved and the other aspects also can be improved since smart factory and IIoT
allow the manufacturing company to perform device connection, real-time alert

2
and monitoring, and data-analytics. As a side objective of the development of
smart factory in the field of data-analytics is to develop a model for preventive
maintenance. Preventive maintenance is one of the maintenance classification that
can be applied through smart factory. By analyzing the historical data, preventive
maintenance can be modeled based on certain conditions.

On the implementation of smart factory, there are several consideration as a high-

level overview. The scope of smart factory needs to be determined. In this scope,
the data that will be gathered and analyzed also being determined. Then, the
technology stack that will be used on the implementation including the hardware,
software, and communication protocols also being determined. On the
implementation of devices, IIoT is one of the foundation. Smart factory allows to
collect and analyze the data from connected devices. In order to connect the
device, IoT is one of the requirements. The IoT is the type of technology that can
connect physicals object such as machine using wireless and/or wired networks
(Karmakar et al., 2019). On the industrial field, there is IIoT that stands for
Industrial Internet of Things. By using IIoT as a fundamental of smart factory,
manufacturing company will enable to create the most relatable and intelligence
connection. After the integration, the development of preventive models using
historical data also being performed as the data analytics process. Then, the smart
factory is ready to be implemented by briefing the manpower for using and
maintain the system.

The development of smart factory refers to the development of the new system to
support the production activity. There are many methodologies and approaches
that can be used to develop new system as an Instructional System Design (ISD).
One of those is ADDIE that stands for Analysis, Design, Development,
Implementation, and Evaluation. ADDIE is a suitable methodologies since all
steps of this methodology will cover all of the scope of new system development
and all of the phase is related one to another. Moreover, ADDIE is commonly
used on instructional designer activity and also for new developer training to help
the designer and developer build the model (Aldoobie, 2015). The advantages of
ADDIE are dynamic and flexible but still effective. Using ADDIE, smart factory

3
can be developed and the most benefit is that ADDIE methodology is suitable
with the workflow of the project on PT TMC.

1.2 Problem Statement

Based on the background, this research will focus to answer these problem
statements:
1. How to implement smart factory on packout area?

1.3 Objectives

Based on the problem statement, the objectives of this research are:

1. To implement smart factory on packout area.

1.4 Scope

Due to the limitation of resources, time, and company policy, there are several
limitations that affect the scope of the research:
1. The observation was performed on packout process as secondary area.
2. The observation was conducted on October 2022 - March 2023.
3. Smart factory aspects implemented are the IIoT, device connection, real-
time alert and monitoring, and data analytics.
4. Smart factory is implemented to support the machine repairment and
layout changeover activities.
5. Data analytics performed only for preventive maintenance model
development.
6. Mobile application and website are made by third parties.
7. Piloting implementation was conducted on February 2023 - March 2023.
8. Several departments are related to the software development and piloting.

1.5 Assumption

To support the calculation process and analysis of the research, there are several
assumptions applied to this research:
1. The skill of mechanics and technicians are equal.

4
 2. Andon system implemented is standardized by the company.
3. Spareparts for machine repairement are always available.

1.6 Research Outline

Chapter I Introduction

This chapter discusses the introduction of the

problem of the research and the reason for the
improvement. The problem statement stated the
problem that will be solved or improved. The
objectives will answer the problem statement. This
chapter also explain the scope as a result of the
limitation on the observation time, resource, and
others together with the assumption to clear the
scope.

Chapter II Literature Study

Literature study will be the fundamental knowledge

of this research. Related field of books, journals, and
articles are reviewed to ensure the research is linear
and has a fundamental.

Chapter III Research Methodology

This chapter discusses the methods, flows, and

instruments of the research that will be explained in a
systematic sequence in order to improve the current
condition.

Chapter IV Data Collection and Analysis

Data collection and analysis consist of a discussion to

5
 answer the objectives of the research.

Chapter V Conclusion and Recommendation

Conclusion answer the problem statement in the first

chapter. The recommendation is a suggestion for
future research on this improvement.

6
 CHAPTER II
LITERATURE STUDY

2.1 Production System

Production system refers to the transformation process that revamps the resources
into finished goods or services. In the transformation process, there are common
resources required such as capital, labor, machinery, raw material, space, and
other investment referred to as the 5M’s, men, machine, method, material, and
money. The company needs an approach that can systemize the production
system, machinery, and other components with uniform semantics (Gönnheimer
et al., 2020).

Production system can be defined as a collection of resource in the company that

perform the manufacturing process. Production system consist of 2 majors
components and its branches. Figure 2.1 shows the components of production
system (Raphael, 2022).

Figure 2.1 Production System Components

In the production system, facilities became one of the component together with
the manufacturing support system. Facilities consists of the plant, machines, tools,
material handling equipments, inspection equipments, and computer system that
can manage and control the manufacturing process in the company. In the

7
facilities, the arrangement of the machine, equipment, manpower, and tool is also
included since the arrangement will affects the plant layout. Manpower
participation in the manufacturing process can be categorized into three
categories. The categories are manual work system, worker-machine system, and
automated system. Figure 2.2 shows the differences in the visualization.

Figure 2.2 Manpower Participation

In the basic term, a company needs to organize their process design, equipment,
and machines, do plan and control to the production so the result will satisfy the
target and the quality requirements. Manufacturing support system refers to the
functions to support the production facilities to operate efficiently. Manufacturing
support system refers to the procedures and people that manage the production
operation.

2.1.1 Production Changeover

One important factor to determine the type of manufacturing is the product type.
In the manufacturing company, the quantity of the product influence significantly

8
the facilities required. Product quantity refers to the number of product that
produced by the company. There are three ranges that describe the level of
product quantity.
1. Low production rate
The product being produced in the range of 1 to 100 units per year.
2. Medium production rate
The product being produced in the range of 100 to 10,000 units per year.
3. High production rate
The product being produced in the range of 10,000 to millions of units per
year.
On the other side, some companies produce a different product types. Product
variety can be defined as a different product design that has different material or
methods that being produced in one plant. There is a relation between product
quantity and product variety. Figure 2.3 shows the relation between product
quantity and product variety.

Figure 2.3 Relation of Product Quantity and Product Variety

In order to provide the facilities to produce high product types, layout changeover
is adapted. Changeover refers to the activities of changing the facilities to support
production activity. In the actual implementation, changeover between production
time takes so much time and can be categorized as lost production time. The time

9
needed commonly called 3Ups that refers to the activities of clean-up, set-up, and
start-up. Production changeover can be classified as a waste that represents the
process of changing the production line to produce one product into another. In
order to overcome the changeover, there is a concept called system flexibility that
allows the facilities to cope with a certain level or stages of variation without
changeover.

2.1.2 Production Layout

In the production floor, the type of layout is important in order to make the flow
of production, material handling, and manpower is efficient. There are many types
of production layout, the most 3 popular layout are described below.

2.1.2.1 Product Layout

Product layout is a concept of arranging the machine, manpower, and process in
order to manufacture a product. One of the advantages of product layout is that
the production processes on the factory floor are relatively easy to supervise. The
drawback is that the degree of freedom in layout is reduced, and makes difficult to
handle wide range of product variety. This layout type is commonly used in
assembly line.
Product layout includes standard or nearly identical types of production a
relatively large amount of product. Final assembly plants for automobiles, trucks
and home appliances usually designed as a product layout. Conveyor system for
moving product. Product layout are usually fixed route, mechanized and suitable
for high flow rates.

Figure 2.4 Product Layout

10
This condition may serve as a storage location for work-in-progress to reduce the
impact of downtime during operations. A production area along the flow of the
material. Figure 2.4 shows the visualization of product layout.

2.1.2.2 Process Layout

Process layouts group production facilities based on functional similarities. The
products on the factory floor are worked on by moving from one facility group to
another facility group following the sequence of the product processing
operations.

Figure 2.5 Process Layout

The advantage of this layout is that the flexibility of the operating process is quite
high but it creates a disadvantage in material transfer systems which are very
complex and expensive because the material flow is in a zigzag pattern (zigzag
flow). This layout also requires a relatively large floor area. Figure 2.5 shows the
visualization of process layout.

2.1.2.3 Fixed-Position Layout

11
 Figure 2.6 Fixed-Position Layout

Different with the previous 2 layout types, fixed-position layout is a layout in

which the production equipment and manpower is moved to the place where the
product being produced. This type of layout is only used for manufacturing large
products such as building, plane, ships, and other large products. Manpower are
taken to the product manufacturing site with all production machinery and
auxiliary equipment. This layout offers a great deal of flexibility and there is very
little material flow as the manufacturing facility is where the operations take
place.

2.2 Maintenance

Over an item's life cycle, maintenance is the sum of all technical, administrative,
and management operations intended to keep it in or return it to a state where it
can fulfill its intended purpose. Maintenance can be divided into two categories:
corrective (or unscheduled) maintenance, which is performed after a malfunction,
and preventative (or scheduled) maintenance, which is carried out in advance of
failure. A subtype of preventative maintenance called condition-based
maintenance (CBM) entails condition monitoring, assessments, and subsequent
maintenance actions (Schenkelberg et al., 2020).

Planning and carrying out maintenance is a difficult undertaking for any system
with a complex structure. The interdependence of the system's constituent parts
may significantly affect the integrity of the system. The complexity of systems
and maintenance expenses have expanded quickly towards the turn of the century

12
as Industry 4.0 gained traction, and related maintenance planning efforts have
proven to be particularly time-sensitive. The effects of a complex system failure
grow more significant due to economic losses like penalty fees and incurred
environmental damages, in addition to the enormous maintenance expenses
(Özgür-Ünlüakın et al., 2021).

2.2.1 Corrective Maintenance

Corrective maintenance (CM) is a type of maintenance done after a machine or
production facility has been damaged or disturbed and is no longer able to operate
and produce correctly. The mean active corrective maintenance time (MACMT),
which solely includes the active time (including documentation) that involves the
designer, is another name for CM.

Corrective maintenance is one area that calls for a lot of human expertise and
effort. When a system experiences downtime, a human technician monitors the
system, examines the fault, and implements the necessary corrections by
eliminating the fault's cause (Vathoopan et al., 2018). Corrective maintenance is a
process that requires human expertise and judgment. in order to find the broken
component, fix it, and minimize downtime. There are remedial maintenance,
deferred maintenance, and shutdown corrective maintenance.

2.2.2 Proactive Maintenance

In contrast, proactive maintenance, which can be classified as preventive or
predictive, is conducted to stop a component from failing or to lower the
likelihood that it will deteriorate. Both corrective and proactive maintenance
planning involve a number of parameters that influence the maintenance choices
(Schenkelberg et al., 2020).

2.2.2.1 Preventive Maintenance

There are routine maintenance and periodic maintenance. The objective of

preventive maintenance is to make the life time of the machine longer, reduce
downtime, and reduce repair cost.

13
2.2.2.2 Predictive Maintenance

2.3 Smart Factory

2.3.1 Scope
2.3.2 Risks
2.3.3 Technology Stack
2.3.3.1 Hardware
2.3.3.2 Software
2.3.3.3. Communication Protocols
2.3.4 Implementation in Indonesia
2.3.5 Industrial Internet of Things (IIoT)

2.4 Work Flow

2.4.1 Flow Chart

Flow chart is a diagram that shows the steps, decision, input, and output of
carrying out certain process. Each steps are depicted in the form of a diagram and
connected by an arrow or line. Flow chart is important in order to visualize the
functionality of a process. Flow chart makes the visualization clearer, consise, and
reduce the possibility of misinterpretation. Figure 2.10 shows the symbols that are
used in flow chart.

14
 Figure 2.10 Flow Chart Symbols

There are 5 types of flow chart that used by defferent purposes. The list of flow
chart types is follow:
1. Document Flow Chart.
2. Programm Flow Chart.
3. Process Flow Chart.
4. System Flow Chart.
5. Scematics Flow Chart.
In the manufacturing company, the flow chart used to visualize production
process is process flow chart. Figure 2.11 shows the example of process flow
chart.

15
 Figure 2.11 Flow Chart Example

2.4.2 Swimlane Diagram

2.5 Capacity Planning

Capacity planning is a process of calculating the required workload, manpower,

tooling and machinery, and production line in order to satisfy the forecasted
demand. Capacity planning is a management tool. In practice, capacity planning is
a tool to calculate the future capacity requirements largely based on future
forecasted demand. If the demand for goods and services can be forecast with a
sufficient degree of accuracy, capacity can be exercised immediately. In the
manufacturing industry, capacity is defined as the amount that a machine can
produce in a certain amount of time.

2.5.1 Productivity

2.6 Time Study

Time study refers to the study to determine the time standard of certain process of
operation. It is important to understand the concept of time standard. Time
standard can be described as a time required to produce certain product at
manpower’s workstation with these following conditions (Stephens, 2020):
1. Well-Trained Manpower
This condition suggest time study to be conducted on a well trained
manpower to make a standard time. The common mistake of time study is
the manpower that being studied is still beginner to the process so it makes
the standard time greater than it has to be.
2. Normal pace
Normal pace means that the time study needs to be conducted in the
normal conditions where the manpower is perform their task with a normal
efforts. Normal efforst refers to the condition when the manpower can
maintain their pace and feel comfortable, not too slow and not to fast.
3. Only doing specific task

16
 Manpower are trained in a certain type of task, to satisfied that, the time
study also need to be conducted by separated a task into specific task.
2.6.1 Standard Time
2.6.2 Normality Test
2.6.3 Homogeneity Test
2.6.4 Standard Time Calculation

2.7 Andon

2.7.1 First Concept of Andon

2.7.2 Future Andon

2.8 System Development

2.8.1 ADDIE
2.8.1.1 Analyze
2.8.1.2 Design
2.8.1.3 Development
2.8.1.4 Implementation
2.8.1.5 Evaluation
2.8.2 System Architecture
2.8.3 User Interface

2.9 Database Development

2.9.1 Snowflake Approach

2.9.2 Star Approach

2.10 Project Management

2.10.1 Scheduling
2.10.2 Break-Even Point

17
2.11 User Requirements
2.11.1 User Acceptance
2.11.2 User Manual

18
 CHAPTER III
RESEARCH METHODOLOGY

3.1 Research Methodology

The methodology of this research determines the step-by-step of this research.

The flow of the theoretical framework will be the guidance to conduct this
research. Theoretical framework are shown on Figure 3.1.

19
 Figure 3.1 Research Methodology

3.1.1 Initial Observation

Initial observation was conducted on packout area at PT TMC. In the interval time
of October 2022 – March 2023, the observation and initial analysis was performed
under the supervision of the Manager of Industrial and Automation Engineering
department. The research started with the observation and analysis of business
processes in the company. There are three main areas of production process,
primary area, secondary area, and soft-goods.

Figure 3.2 Business Process

Primary area refers to the area where raw material are being processed to become
Work-in-process (WIP). The type of layout applied in the primary area is process
layout where the production process is divided by their process. Can be seen in
Figure 3.2 with light-red color. The secondary area focuses on doll head making,
hair planting, grooming, and packing out. Can be seen in Figure 3.2 with yellow
color. The layout applied in the secondary area is process layout and product
layout. Rotocast, BBD, and rooting use process layout. Grooming and pack out
use product layout. Soft-goods area focuses on making a soft-gods parts of the
finished product such as shirt, jeans, pants, and jacket through the process of die
cut and sewing. Can be seen in Figure 3.2 with green color.

20
Facilities available in order to support the production process can be categorized
as two main categories, tangible facility and intangible facility. Tangible facility
refers to the facility provided that can be used physically including area, tools,
machines, and devices such such as computer. On the other side, intangible
facility refers to the facility provided that cannot be used physically including
tracker system and data.

One of the biggest toy manufacturers in the world, PT TMC, is likewise dealing
with the issue of efficiency on their manufacturing system. Work-in-progress
(WIP) components are put together into a single packed and finished product
during the packout process, which serves as their secondary process. The packout
production floor has a nearly 10,672 m2 surface, measuring 115 meters in length
and 92.8 meters in breadth. There are 124 active lines in this area, and 514
machines service those lines. As part of PT TMC's goal to become a leading
manufacturer that maximizes efficiency, numerous observations have been made
to identify waste and raise efficiency.

3.1.2 Problem Identification

In order to comprehend the workflow and also examine the shortcomings, the
layout changeover workflow was reviewed and analyzed. The workflow was
found to be inefficient since it takes a long time to gather information from many
sources, such as layout changeover summaries, layout drawings, and details of the
machines utilized, which are still on paper or printed out, and because the
machine's location isn't known. As was previously stated, PT TMC, one of the toy
manufacturers, is similarly challenged by the sheer volume and variety of its
products. The range of packout processes are caused by this condition. There were
10,500 layout changeover in 2022, according to the layout changeover report.
While a single layout switch can take 15 minutes on average, a simple layout
switch just takes 5 minutes, and a sophisticated layout switch takes 20 minutes.
Based on the data mentioned, this problem become strongly urgent to be solved.

Machine downtime is another issue that must be solved if the production floor is
to operate as efficiently as possible. It is well recognized that machine downtime

21
can potentially lower production output, particularly for manufacturing that uses
product layout. So, it is evident that less machine downtime is required in order to
maximize machine availability. According to complaints of machine problems,
there were 6,294 downtimes with an average repair time of 15.92 minutes.
Nevertheless, because the current approach merely relies on Andon light, response
time is not taken into account. Moreover, the 10,672 m2 covering area of the
mechanic results in a longer response time. Several grievances were made over
the length of time it took for the mechanic to detect a machine breakdown. Even
though the average response time is 15 minutes, it can sometimes take an hour.

According to the explanation, it is necessary to create a new system that can assist
with layout changeover and machine repair processes. The reduction of layout
changeover time is the goal of the enhancement of layout changeover. Reducing
the mechanics' response time is one of the goals of machine repair. However, the
main objective is to implement the concept of smart factory. The concept of smart
factory will only be developed and implemented to machine repairment and layout
changeover. On the other side, due to the limitation of resource, time, and
company pilocy, there are several limitations and assumptions that affect the
scope of the research.

3.1.3 Literature Study

A literature study is a theoretical guide for the research in order to maintain the
research validity. After the problem is identified and objectives was set, the
foundation of knowledge is needed. The literature study consists of a brief
explanation of the related topic that will support the research. In this research, the
literature study as a reference comes from journals, books, and related academic
articles. The following list is the topics of the literature study:
1. Production system.
2. Production change over.
3. Layout type.
4. Maintenance Category.
5. Smart factory.
6. Workflow.

22
 7. Manpower capacity and productivity.
8. Time study.
9. Andon.
10. System development (ADDIE).
11. Database development.
12. Project management.
13. User requirements.

3.1.4 Data Collection

To conduct the research and satisfy all the objectives, there are several types of
historical data that need to be analyzed. The required data is explained in the
following list:
1. Packout shiftly report
Packout shiftly report is a data collection of machine downtime. This data
collection has the information of date and time, line number, machine
type, machine number, machine detail issue, action, start time, finish time,
and mechanic. By this data collection, the standard repair time can be
calculated by categorization of machine downtime first. This data can be
categorized as secondary and quantitative data.
2. Packout layout changover
Packout layout changeover is a data collection of layout changeover. This
data collection has the information of schedule run date and shift, schedule
preparation date and shift, line number, and toy number. This data can be
categorized as secondary and quantitative data.
3. Workflow of mechanic team
This data is a primary data as the result of initial observation. This data
shown as a swimlane diagram that consists of 4 columns as a category of
manpower. There are operator, line leader, mechanic, and mechanic
leader. The swimlane diagram shows the detailed process of mechanic
workflow from the beginning until the end.
4. Workflow of layout team
This data is a primary data as the result of initial observation. This data
shown as a swimlane diagram that consists of 5 columns as a category of

23
 manpower. There are planner, layout leader, layout personnel, piloting
technician, and industrial engineering clerk. The swimlane diagram shows
the detailed process of layout changeover workflow from the beginning
until the end.

3.1.5 Data Analysis

In order to satisfy and answer the objectives of the research, data analysis of data
collection is required. Based on the objectives also, the data analysis can be
focused. The data analysis of this research will contain the analysis of:
1. ADDIE Methodology:
a. Analysis
b. Design
c. Development
d. Implementation
e. Evaluation
2. ADDIE Methodology Loop.
ADDIE methodology has a loop on the relation between evaluation stage
and the other stages. This loop needs to be reviewed to make the system
better.
3. Advantages of Smart Factory Implementation.
Current and improved condition will be compared in term of workflow
and efficiency.
4. Investment and Cost Savings Calculation.
Investment and cost savings will be calculated, then break even point can
be determined.

3.1.6 Conclusion and Recommendation

The conclusion will answer the objectives of the research in a brief explanation
that comes from the data analysis. The recommendation provides information
about future research and implementation that can be improved in the future.

3.2 Research Framework

24
The research framework discusses the detailed version of the research
methodology. In the process of conducting the research, this framework will be
the guidance. Figure 3.3 shows the research framework of this research.

The research framework shows the initial observation will gather the data
collection. ADDIE methodology is used in this research. Starts from analysis,
design, develop, implement, and evaluate the system. After that, there will be a
comparison of current condition and improved condition. Investment and cost
savings also will be calculated.

ADDIE methodology is used to develop the smart factory. Every stages on

ADDIE methodology has their own purposes. The following list explains the
stages on ADDIE methodology:
1. Analysis
a. Shortcmings determination.
b. Users and Stakeholders Identification.
c. User Requirements Identification.
d. Stakeholder Requirements Identification.
e. System Requirements Determination.
2. Design
a. Smart Factory Scope.
b. System Architecture Design.
c. Technology Stack.
d. User Interface Design.
e. Data Requirements.
f. Database Design.
3. Development
a. User Manual.
b. Setting Up Technology Infrastructure.
c. Preventive Maintenance Model Development.
4. Implementation
a. User Briefing and Training.
b. Piloting Implementation.

25
5. Evaluation
a. User Acceptance Test.
b. Analyze the Feedback.

26
Figure 3.3 Research Framework

27
 CHAPTER IV
DATA COLLECTION AND ANALYSIS

4.1 Initial Observation and Data Collection

In this research, the data collection can be divided into two categories, primary
data collection and secondary data collection. Primary data collection is the data
that being taken by the researcher in order to support the research. Otherwise,
secondary data collection is the data that being taken by someone else. In this
case, secondary data is the data collected by PT TMC as their tracking data
collection.

4.1.1 Primary Data Collection

Primary data collection can be divided into two categories, workflow of mechanic
team and workflow of layout team. The workflow shown using swimlane diagram
as one of the tools to describe the flow.

4.1.1.1 Workflow of Mechanic Team

The workflow of mechanic team is the result of the observation and interview
with mechanic and mechanic leader. There are 4 manpower roles that related to
the mechanic team, operator, line leader, mechanic, and mechanic leader. The
flow started when the operator noticed machine abnormality. Then, they will
report it to the line leader. Line leader till press the red button of Andon and the
light will turned on. They need to wait until mechanic notice the red light and
respond by coming to the line location and start to repair the machine
abnormality. After the mechanic finish to repair the machine, they are required to
fill in Microsoft Form that will collect the detailed information about machine
downtime. The time needed for the mechanic notice the red light is response time.

There is different on the implementation of Andon on PT TMC and another

company. Because in packout area the layout adapted is product layout using
conveyor, there will only one Andon for each line eventhough there are several
machine used. When the abnormality of the machine started to happen, then the

28
line leader needs to press the red button and the red light will turned on. There are
also differences on the means of andon light. In PT TMC, red light represent a
machine downtime, yellow light represent in-house material issues, and green
light represent vendor material issues.

Figure 4.1 shows the workflow of mechanic team based on the description in
advance. Based on the figure, it can be concluded that PT TMC adapt and
implement corrective maintenance activity where the maintenance is performed
when there is an issue. Based on the figure, there will be 2 categories of time
required on mechanic workflow. The first is response time and the second is
repair time. The total of time required will be downtime.

Figure 4.1 Workflow of Mechanic Team

The Microsoft Form will collect the detailed information about machine
downtime. There are data about date, shift, activity, KPK (Employee ID number),
line number, issues, start time, and finish time. This data will be transformed and

29
loaded into Microsoft Power BI to track the frequency of downtime, average time
of downtime, and the issues solved per mechanic. The Microsoft Power BI will
evaluated by Mechanic Leader, Manager of Industrial and Automation, and
Director of Engineering.

4.1.1.2 Workflow of Layout Team

Layout team is a team that responsible to perform the task to change the
composition and sequences of tools and machine that being used on certain line.
Because on packout area PT TMC adapted product layout, different product will
have different composition and sequences of tools and machine. The workflow of
layout team is the result of observation and interview with layout leader and
layout personnel.

There are 5 manpower roles related to the workflow of layout team, planner,
layout leader, layout personnel, piloting technician, and industrial engineering
clerk. The planner will schedule the production including for packout area. Once
the schedule is being released, layout leader will make the summary of the layout
changeover. This summary will be shared to WhatsApp group of Layout Team
and distribute the job and responsibilities for each layout personnel. Piloting
technician will give the drawing of the layout to layout leader by attaching the
hard copy of layout drawing on the layout leader locker. Layout leader will scan
the hard copy and upload it to Google Drive. Once the schedule of changeover,
the layout personnel will perform their responsibilities.

At the end of the week, layout leader will give the actual changeover summary to
industrial engineering clerk. Industrial engineering clerk will type the summary to
Microsoft Excel. This Microsoft Excel become the database of Layout
Changeover Report on Microsot Power BI. Figure 4.2 shows the workflow of
layout team.

Microsoft Power BI will be reported to the Manager of Industrial Automation and

Director of Engineering. The report will contain the total layout changeover, total
layout changeover by shift, and total layout changeover by line type available on
PT TMC.

30
The explanation described there are several shortcomings of current workflow that
are listed below:
1. Using personal message platform as the platform to share the layout
changeover summary.
2. Sharing the confidential information through personal message platform.
3. The actual layout changeover cannot be tracked real-time.
4. The tools and machine quantity details are not provided.
5. Industrial engineering clerk needs to input the actual layout changeover
summary at the end of the week.

Figure 4.2 Workflow of Layout Team

31
4.1.2 Secondary Data Collection
Secondary data collection consists of packout shoftly report and layout
changeover report. Packout shiftly report is a data collection for machine
downtime. On the other hand, layout changeover report is data collection for
layout changeover.

4.1.2.1 Packout Shiftly Report

Packout shiftly report is a data collection of machine downtime with the detailed
data about:
1. Date.
2. Shift.
3. KPK (Mechanic ID).
4. Mechanic Name.
5. Line Number.
6. Machine Type.
7. Machine Number.
8. Downtime Reason.
9. Action.
10. Start Time.
11. Finish Time.
12. Downtime Status.
13. Remarks.

As mentioned in workflow of mechanic team, mechanic needs to fill in the

Microsoft Form about machine downtime after they finish repairing the machine.
Packout shiftly report has 9882 data about machine downtime that has been
collected from January 28th, 2022 – March 3rd, 2023.

The graph shows the count of machine downtime based on week ending. Based on
the graph, the highest count of downtime happened on 11/4/2022 - 11/10/2022
with total of 493 machine downtime. Those data can be analyzed deeper to see the
pattern on the peak or busiest period of a year for machine repairment activity.

32
 Machine Downtime
600

500
Count of Machine Downtime

400

300

200

100

0
22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 23 23 23
/20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20 /20
9 8 1 1 2 7 7 8 9 9 9 1 1 2 3 3 3 4
/2 /1 /1 4/ /2 /2 /1 7/ /2 /1 9/ /2 /1 2/ /2 /1 2/ /2
<1 - 2 - 3 2 - - 4 - 5 - 6 2 - - 7 - 8 2 - - 10 - 11 - 1 - 12 - 1 3 - - 2
2 2 2 2 2 2 2 2 2 2 2 3 2 3
02 02 20 02 02 02 20 02 02 20 22 22 02 22 02 20 02
2 /2 5/2 26/ 6/2 1/2 1/2 /2/ 3/2 3/2 /3/ /20 /20 6/2 /20 7/2 28/ 8/2
1 3/ 3/ /1 /2 /1 7 /2 /1 9 5 /5 /2 7 1/ 1/ /1
2/ 4 5 6 7 8 /1 1 1 /1 2
10 1 1 12

Week Ending

Figure 4.3 Count of Machine Downtime

Figure 4.4 shows the machine downtime by shift. Machine downtime on shift 2
leads with the percentage of 64%, followed by on shift 1 with the percentage of
34%, and the last is shift 3 with the percentage of 2%. This historical data can be
used to determine the right and preferable time to conduct preventive
maintenance.

Machine Downtime by Shift

2%
34% S1
S2
S3
64%

Figure 4.4 Machine Downtime by Shift

33
The busiest shift for mechanic is on shift 2 which has 64% of workload of one-
day workload, followed by shift 1 with 34%. Since shift 3 is counted as an
overtime, the right time to perform preventive maintenance is on shift 1.
However, the schedule is not fixed. Preventive maintenance also can be performed
on shift 2.

The MTBF and MTTR are able to calculated using formula. Mean time between
failures are refers to the average of the time between two failure that are
consecutive. Meanwhile for mean time to repair refers to the average of time
needed to repair the machine. The following are the formulas to calculate MTBF
and MTTR.

MTBF or mean time between failure can be calculated using the following
equation.

Total Available Time−Total Downtime

MTBF=
Number of Downtime

(4-1)
PT TMC applied 6 working days per week and 8 working hours per day. Since the
data were taken from January 28th, 2022 – March 3rd, 2023. The total available
time can be calculated. On that time interval, there are 399 working days and 21
public holidays. There are also 514 machines used. The total available time in
minute can be calculated.

Total Available Time= (399−21 )∗8∗60∗514=93260160 minutes

Total downtime can be calculated on excel using Pivot Table. The total downtime
is 237654 minutes. The number of downtime has been mentioned in advance with
9882 times. Then, the MTBF can be calculated.

93260160−237654
MTBF= =9413.32 minutes=6.53 days
9882

The MTBF is 6.53 days. This number tell the performance of the machine and
mechanic. The greater the MTBF, the better.

34
Meanwhile for calculate the MTTR or mean time to repair, following equation is
used.

Total Downtime
MTTR=
Number of Downtime
(4-2)
237654
MTTR= =24.09 minutes
9882

On the other side, since MTTR calculate the mean time to repair, the smaller the
duration the better. In this condition, the MTTR is 24.09 minutes.

Based on the data of 11/4/2022 - 11/10/2022, Total of machine downtime can be

calculated. Figure 4.5 shows the total of machine downtime duration. Based on
graph, sealing blister become the highest total machine downtime followed by
spotwelding for J-hook and carton sealer. This historical data can be used to the
development of preventive maintenance model.

Figure 4.5 Machine Downtime

The model developed for preventive maintenance will have machine list priority.
The priority will be based on figure 4.5 by considering the most time consumed

35
machine downtime. The highest machine downtime was from sealing blister
machine with 281 minutes, followed by spotwelding j-hook with 40 minutes, and
carton sealer UPLIN with 38 minutes.

On the other side, the available data also can used to calculate the manpower
productivity. There are 11 mechanics that support the machine maintenance
activity on shift 1 and 2. Manpower productivity will be calculated for each
mechanic. The manpower productivity can be calculated using Equation (4-3).

Manpower Productivity=
∑ of Repair Activity for 1 week
Available Time of 1Week
(4-3)
For the calculation of available time of 1 week in the unit of minutes, Equation (4-
4) is used.

Available Time of 1 Week=Work days∗work hours per day∗60

(4-4)
PT TMC applied 6 work days per week and 8 work hours per day. Based on the
calculation, available time of 1 week is 2880 minutes.

Available Time of 1 Week=6∗8∗60=2880 minutes

After that, the sum of downtime duration per mechanic was calculated using
pivot. Figure 4.6 shows the manpower productivity. The orange-constant line
shows the maximum productivity per week and the bar chart shows the sum of
downtime duration.

36
 Manpower Productivity
3000

2000
Sum of Downtime (min)

1000
Sum of Min
0
O H D RI KI DI AT A DI TO TO
I Average of Capacity
G A G
G AT WA SAE UL TA AY A BA AN AR
N F U U M R D IN A S I
PA AL J K M HA HI T S AD SU UG
P S JI R I S
SU U U NU OG HM KO
U AG M S O E
IY PA R ET
D M
A A
SL

Mechanic

Figure 4.6 Manpower Productivity

Based on Figure 4.6, most of the manpower only use lower than 50% of their
maximum productivity. Eventhough this data was not taken real-time, this data
can be a guideline for productivity improvement by implementing smart factory.

Manpower Capacity

16%

Used Capacity
Unused Capacity

84%

Figure 4.7 Manpower Capacity

Figure 4.7 shows the manpower used capacity and unused capacity. The capacity
used by mechanic in aggregate was only 16%. Because this data was not taken
real-time, it is hard to monitor on the same day. By the implementation of smart
factory, the activity and productivity of mechanics can be tracked real-time and

37
will lead to the balanced workload distribution and reduced unused capacity of
mechanic by assigning certain mechanic to support the other activities.

4.1.2.2 Layout Changeover Report

Layout changeover report is a data collection of layout changeover with the
detailed data about:
1. Preparation date.
2. Preparation shift.
3. Production date.
4. Production shift.
5. Line number.
6. Change to Toy 1.
7. Change to Toy 2.
8. Change to Toy 3.
To analyze the data collection, the data was grouped by the week ending. Figure
4.8 shows the total changeover by week ending. Based on the graph, the peak of
changeover was on the period of 06/05/2022 – 06/11/2022.

Total Changeover
400
300
Count of Changeover

200
100
0
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3
02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02 02
9 /2 1/2 5/2 9/2 3/2 6/2 0/2 3/2 7/2 1/2 5/2 9/2 2/2 6/2 0/2 4/2 4/2 8/2 1/2 5/2
/2 /1 /2 7/ /2 8/ /2 9/ /1 0/ /1 /2 /1 /2 /1 /2 /1 /2 /1 /2
<5 - 6 - 6 2 - - 7 2 - - 8 2 - - 9 - 1 - 10 - 10 - 11 - 11 - 12 - 12 - 1 - 1 - 2 - 2
22 22 02 22 02 22 02 22 22 2 2 2 2 2 2 23 23 23 23
/20 /20 /3/2 /20 1/2 /20 8/2 /20 /20 202 202 202 202 202 202 /20 /20 /20 /20
5 9 7 17 /3 14 /2 11 25 9/ 3/ 6/ 0/ 4/ 8/ /8 22 /5 19
6/ 6/1 7/ 7 8/ 8 9/ 9/ 10/ 0/2 11/ 1/2 12/ 2/1 1 1/ 2 2 /
1 1 1
Week Ending

Figure 4.8 Total Changeover

Figure 4.9 shows the preparation shift of layout team. Based on the graph, the
highest rate of preparation was on shift 3. With the percentage of 47%, followed
by shift 2 with 44%, and shift 1 with 9%.

38
 Layout Preparation Shift

9%

S1
47% S2
S3
44%

Figure 4.9 Layout Preparation Shift

Different with packout shiftly report that has richer data collection, the layout
changeover report only has several data that cannot be fully analyzed to become a
usefull data interpretation. Layout time was not collected so the manpower
productivity cannot be calculated.

4.2 Analysis

The development of a new system to assist in production is referred to as the

development of a smart factory. There are numerous methods and techniques that
can be applied when creating new systems for instructional system design. (ISD).
One of those is ADDIE which stands for Analysis, Design, Development,
Implementation, and Evaluation. ADDIE methodology helps the development of
the system by dividing the development into stages. In this research, the stages
will be divided into numerous sub-stages.

Analysis is the first stage of ADDIE methodology. Analysis stage consists of

shortcomings determination, user and stakeholder identification, user
requirements identification, stakeholder requirements identification, system
requirements determination.

4.2.1 Shortcomings Determination

39
The research started with the observation and analysis of business processes in the
company. There are three main areas of production process, primary area,
secondary area, and soft-goods.

Figure 4.10 Overall Production Section

Since the focus of the research is on the secondary area, the explanation will be on
secondary area only. Figure 4.10 with yellow color. The secondary area focuses
on doll head making, hair planting, grooming, and packing out. The layout applied
in the secondary area is process layout and product layout. On packout area, there
is auto and manual. Auto refers to the process of packout using machine such as
autoblister. However, the automation is only for blister process.

The packout production floor has a nearly 10,672 m2 surface, measuring 115
meters in length and 92.8 meters in width. Figure 4.11 shows the layout of
packout area on top view. There are 124 active lines in this area, and 514
machines support those lines.

40
 Figure 4.11 Packout Area

Packout as the process on secondary area handled by Industrial Engineering

Department. The responsibilities of Industrial Engineering Department can be
categorized as two categories called repetitive jobs and projects. Repetitive job is
a responsibilities that will be performed everyday that related to the piloting stage
of production. Repetitive job become more efficiently performed by implementing
engineer balancing and using web-based information system to track all of the
works, issues, and solutions.

As one of the responsibilities, Industrial and Automation Department is required

to perform the improvement such as machine development, machine life cycle
management, machine maintenance, and layout changeover. The most dynamic
responsibilities are machine maintenance and layout changeover since this tasks
are performed on daily-basis. Started with the report from the production
department that mention the target output was often to not achieve the target
because of the machine downtime. Machine maintenance process was observed to
identify the shortcomings of current workflow. Machine downtime is the

41
summarization of response time and repair time. Based on the shiftly packout
report, there is nothing wrong with the repair time that has the average of 15
minutes. After more observation, the shortocmings was found on the response
time of mechanic to relize there is machine problem on the line.

The packout process modified the product layout, with the conveyor line serving
as the assembly line. In line with product variation, the toy number also affects
how the product is set up out. This process is known as layout changeover. The
process of changing the tools, machines, and sequences in order to facilitate
production is known as layout changeover. There were 10,500 layout changes in
2022, according to the layout changeover report. While a single layout switch can
take 15 minutes on average, a simple layout switch just takes 5 minutes, and a
sophisticated layout switch takes 20 minutes. In order to comprehend the
workflow and also examine the flaws, the layout changeover workflow was
reviewed and analyzed. The workflow was found to be inefficient because it takes
a long time to gather information from different sources, such as layout
changeover summaries from the leader, layout drawings that needs to be scaned
and uploaded to personel Google Drive, and details of the machines used, which
are still on paper or printed out, and because the machine's location isn't known.

According to the explanation, it is crucial to create a new system that can assist
with layout changeover and machine repair processes. The use of smart factory
has emerged as a suitable means of overcoming and achieving those goals. The
objective is the implementation of smart factory since they enable manufacturing
companies to execute device connection, real-time alert and monitoring, and data
analytics.

4.2.2 User and Stakeholder Identification

After the shortcomings determination, the objective of the system development
became clear. The next step in analysis stage is to identify the user and
stakeholder related to this development. By identifying the user and stakeholder,
the system developed in the future will be most likely to meet their needs and
expectations. Besides that, this step is also important in creating user-centered
design. It will reduce the costs of development stage due to the changes. It is

42
related to the next step which is the identification of user and stakeholder
requirements.

Figure 4.12 Organizational Chart of Engineering

Figure 4.12 shows the organizational chart of engineering. Since the focus of the
research is on secondary process, in organizational chart will be focus on the
Industrial and Automation. There is Manager of Industrial and Automation that
leads:
1. Associate Manager of Industrial Engineering.
2. Associate Manager of Manufacturing Engineering.
3. Senior of Tooling Engineering.
4. Senior of Industrial Engineering.
5. Senior of Automation Engineering.
6. Manager of Digital Transformation.

All of those people has their own responsibilities that are related to each other.
However, there are people that mainly responsible on machine repairment and
layout changeover. There are Senior of Tooling Engineering, Associate Manager

43
of Industrial Engineering, and Manager of Industrial and Automation itself. Based
on that, the stakeholders identified as the following list:
1. Manager of Industrial and Automation.
2. Associate Manager of Industrial Engineering.
3. Senior of Tooling Engineering.

Meanwhile for the users of the developed system, there are mechanic team and
layout team. Figure 4.13 shows the users organizational chart.

Figure 4.13 Users Organizational Chart

Senior of Tooling Engineering leads and supervises mechanic team and layout
team. Mechanic team consists of its leader and personnel. The same with layout
team, there is layout leader and layout personnel.

4.2.3 User Requirements Identification

User requirements refers to the requirements of the user in the term about the
functionality and features available. In this research, the user requirements are
gathered through observation of current system and interview related people. User
requirements are important in the process of developing new system in order to

44
understand the needs of the future user. Since the user categorized as four, the
user requirements also will be grouped based on the user category. Table 4.1
shows the user requirements.

Table 1. User Requirements

User Requirements

Mechanic Leader 1. The mechanic leader is able to assign

mechanic personnel to certain TicketID.
2. The mechanic leader has all mechanic
personnel features.
Mechanic Personnel 1. The mechanic personnel is able to accept and
reject a TicketID.
2. The mechanic personnel is able to accept a
TicketID through notification and overall
machine problem menu.
3. The mechanic is able to call a friend if they
think they cannot do the repairment alone.
4. The mechanic personnel is able to see the
duration of machine downtime.
5. The mechanic personnel is able to choose semi
finish if they work shift has been ended.
6. The mechanic personnel is able to choose
downtime reason based on the available
category on drop-down.
7. The mechanic personnel is able type detailed
downtime reason.
8. The mechanic is able close the TicketID after
the repairment has been finished.
Layout Leader 1. The layout leader is able to input the layout
changeover schedule through website that
become TicketID.
2. The layout leader is able to see and download

45
 User Requirements

the layout changeover schedule summary in

the format of JPEG and PDF.
3. The layout leader is able to monitor the
TicketID through website.
4. The layout leader is able to see the status of
machine quantity and layout drawing through
website.
5. The layout leader has all layout personnel
features.
Layout Personnel 1. The layout personnel can see and download
the summary of layout changeover.
2. The layout personnel can see the machine
detail about the location and condition.
3. The layout personnel can see the TicketID
status and take the TicketID.
4. The layout personnel is able to identify the toy
number.
5. The layout personnel is able to see the layout
drawing of related toy number.
6. The layout personnel is able to see the
machine quantity needed.
7. The layout personnel is able to see the nearby
machine location.
8. The layout personnel is able to scan all of the
machine used to close the TicketID.
9. The layout personnel will get the notification
once the Andon light for layout is pressed.

However, in order to support all of those user requirements, there are common
user requirements that are need to be provided, such as:
1. Usability:

46
 a. The system is easy to use with coherent navigation.
b. The system is user-friendly with coherent navigation.
c. Every button on the system will appear.
d. The system built with the attention on user experience.
2. Security:
a. The system required PIN everytime the application is being
opened.
b. The system is able to reset the PIN and password by verifying the
registered e-mail.

4.2.4 Stakeholder Requirements Identification

Based on the pervious explanation, there are 3 stakeholders:
1. Manager of Industrial and Automation.
2. Associate Manager of Industrial Engineering.
3. Senior of Tooling Engineering.

As someone whose role is to oversee and monitor the performance of users, the
features required by a stakeholder are slightly different from those of the user. The
stakeholder requirements are in the form of report that generated from the data
collected by the system. Data analytics are required to transform the raw data into
report that represent the data. Table 4.2 represent the stakeholder requirements.
Table 4.2 Stakeholder Requirements

Stakeholder Requirements
Main Dashboard (machine problem) 1. Percentage of line availability.
2. Line utilization.
3. 24-hours trend of downtime.
4. Top 5 machine downtime.
5. Top 5 Line downtime.
6. Top 5 slowest repair time by line
(sum).
7. Top 5 slowest response time by
line (sum).
8. Top 5 slowest repair time by line

47
 (average).
9. Top 5 slowest response time by
line (average).
10. 24-hours trend of response time.
11. 24-hours trend of repair time.
Line (machine problem and layout Line status with color indicator that
changeover) represent the condition of the line.

Machine Problem 1. Filter in the categories of line,

machine, year, and month.
2. Top 5 problematic machine –
Total of downtime.
3. Top 5 problematic machine –
Average of downtime.
4. Top 5 slowest response time by
machine.
5. Top 5 slowest repair time by
downtime reason.
Manpower (machine problem) 1. Logged mechanic status and
location.
2. Real-time TicketID released.
3. Real-time work order.
Layout Changeover 1. Total layout changeover trend.
2. Total layout changeover by shift
3. Total layout changeover by line.
4. Total layout changeover duration.
5. Layout changeover duration by
line.
Advanced Data Analytics 1. Preventive Maintenance.
2. Manpower Productivity.
3. Manpower KPI.
4. Manpower XP Level.

48
4.2.5 System Requirements Identification
System requirements refers to the description of the system including the
functions and capabilities that the system needs to have. System requirements will
be based on user requirements and stakeholder requirements. System requirements
playing major roles in the development since system requirements serve as a
blueprint of the system. System requirements consists the two main elements,
non-functional requirements and functional requirements.

Non-functional requirements refers to the performance, usability, security,

scalability, and reliability of the system. Non-functional requirements ensure the
system is effective and efficient when the user use. Meanwhile, functional
requirements refers to the ability of the system to perform several process and/or
produce outputs. The system is required to be able to perform functional
operations. Table 4.3 shows the non-functional and functional requirements.

Table 4.3 System Requirements

Element Criteria Detail

Non- Performance 1. The system is able to accommodate at

Functional
least 100 users.
2. The system is able to accommodate at
least 1000 TicketID of machine
dowmtine per day.
3. The system is able to accommodate at
least 1000 TicketID of layout
changeover per day.
Usability 1. The system can be used by all
stakeholders and users.
2. The system support the mechanic team
and layout team.
3. The system is user-friendly with
coherent navigation.
4. Every button on the system will

49
Element Criteria Detail

appear.
5. The system built with the attention on
user experience.
Security 1. The system required the its user to
sign-up if they haven’t been have the
account.
2. All new user needs to be verified by
super admin. Super admin is Senior of
Tooling Engineer.
3. The system required the user to sign-in
if they have an account.
4. The system required PIN everytime the
application is being opened.
5. The system is only can be accessed
using PT TMC devices.
6. The system is able to reset the PIN and
password by verifying the registered e-
mail.
Scalability 1. The system needs to be able to be
adjusted to the needs of the user.
2. The system is able to accommodate
large number of data volumes.
Reliability 1. The system needs to be performing
well everytime at least 10 years after
being released and fully used.
Functional Common 1. The user is able to change the language
Requirements
on the application.
User 1. The new user is able to create a new
Management
account using PT TMC email.
Requirements
2. The new account needs to be verified
by super admin.

50
Element Criteria Detail

3. The user is able to change the

password.
4. The user is able to change the PIN.
5. The user is able to see the history of
TicketID that being taken by them.
Reporting 1. The system is able to show the report
Requirements
of machine problem TicketID and
layout changeover TicketID.
2. The system is able to show the
productivity of the user.
3. The system is able to show the XP
level of the user.
Notification and 1. The system is able to release the
Alert
notification once the Andon button is
Requirements
pressed.
2. The system is able to release the
notification once mechanic personnel is
being assigned to certain TicketID by
mechanic leader.
3. The system is able to show the history
of notification.
Integration 1. The system is able to be connected to
Requirements
IE New Toy Tracker Website operated
by Digital Transformation Division of
PT TMC.
2. Machine availability on layout
changeover menu is related to the latest
status of machine on machine problem
menu.
Search and 1. On machine problem menu, the system
Filter
is able to be searched based on the
Requirements

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Element Criteria Detail

location.
2. On machine problem menu, the system
is able to be filtered by TicketID status.
3. On layout changeover menu, the
system is able to be filtered based on
the date and shift.
Machine 1. The system is able to show the
Problem Menu
TicketID released on related day on
table form with click-able ticket status.
2. Mechanic leader can assign certain
ticket to mechanic personnel.
3. The system will show the pop-up of
confirmation for accepting a ticket.
4. The mechanic is able to scan machine
barcode and the MachineID and
Machine Name will automatically
filled.
5. Once the ticket being taken and the
mechanic started to repair, the
mechanic can call a friend to help to
finish the ticket.
6. If the TicketID is still being actively on
progress when the shift is changed, the
semi finish option will appear.
7. TicketID only can be closed if the
downtime reason and detailed
downtime reason are filled.
8. Downtime reason is categorized drop-
down and detailed downtime reason
can be filled by typing.
Layout 1. Layout leader can input the changeover

52
 Element Criteria Detail

Changeover through website.

Menu
2. Layout leader can monitor the
TicketID of layout changeover real-
time.
3. The system is able to show the
TicketID released on related day on
table form with click-able ticket status.
4. The summary of layout changeover is
download-able in JPEG and PDF
formats.
5. Machine detail is shows the
MachineID, location, and condition.
6. The system will show the pop-up of
confirmation for accepting a ticket.
7. Once the ticket being accepted, the
detail about toy number, machine
quantity used, and layout drawing can
be shown.
8. Ticket can be closed only if the layout
personnel has scan all machine used on
the line.

4.3 Design

Design is the second stage of ADDIE methodology. On the other side, design
stage focus on the smart factory scope, system architecture, technology stack, user
interface design, data requirement, and database design.

4.3.1 Smart Factory Scope

Smart factory is a concept about device connection in the factory that is advanced
data-analytics using sensors, Internet of Things (IoT) and machine learning (ML).
Using sensors and IoT, smart factory allows the communication interdevices so

53
the real-time monitoring is possible to happen. As mentioned on the scope of this
research, the smart factory aspects that are implemented in this research are:
1. Industrial Internet of Things (IIoT)
2. Device connection
3. Real-time alert and monitoring
4. Data-analytics to develop preventive maintenance model.

Instead of predictive maintenance, this research will adapt preventive

maintenance. Predictive maintenance requires the installation of sensors as the
vision of the monitoring system. The installation of sensors are near to imposibble
in the near future at PT TMC on packout area because of this reasons:
1. Type of Production Line.
There are 6 type of production lines that has their own characteristics.
2. Self-developed machine.
The machines utilized in packout area are self-developed machine with the
mechanical and design limitation to install the sensors needed. Moreover,
the machine is also relatively inexpensive and the cost of developing a
predictive maintenance will not worth the investment.
3. Manual operation.
Most of packout machines are manual opration with the operator to
operate the machine. There is human ability to feel and determine the
condition of the machine.
4. Low-tech machine.
Most of packout machines doesn’t have complex moving parts. This
condition doesn’t requires the level of monitoring as more complex
machinery.

4.3.2 System Architecture

System architecture refers to the principles that define the method of developing a
system. Figure 4.14 shows the system architecture of developed smart factory.

54
 Figure 4.14 System Architecture

The line leader will interact with andon button on production line. IoT box will be
installed on andon button in order to make the andon button communicate. The
communication protocol used is Wi-Fi in the access point as a central transmitter.
The signal will be transferred to the local server and continued to PT TMC
database. The signal received will be shown on the mobile application. Then,
Mechanic team and layout team can execute their task.

Moreover, layout leader input the layout changeover schedule to the system and
mechanic leader assign the mechanic personnel. Those data will be stores on PT
TMC database and shown on mobile application. As a data-analytics process,

55
then, there will be a dashboard, visualization, log, and data report to the
stakeholders.

4.3.3 Use Case Diagram

Figure 4.15 Use Case Diagram of Mobile Application

Use case diagram is a diagram used in the information system design to identify
the interaction between the actors and the system. Use case diagram commonly
consists of the actors, the system, and their interaction. The interaction can be
association, include, and exclude. Interaction symbolized with arrow. Meanwhile
for include and exclude symbolized by dashline. Figure 4.15 shows the use case
diagram of the mobile application.

Mobile application will be mainly used by 4 actors, mechanic personnel, layout

personnel, mechanic leader, and layout leader. However, there are 2 actors that are

56
not interacted directly to the mobile app but still their action affect the mobile
application. The four main actors are able to register and login. New registration
will requires validation by senior of tooling engineer. On the mobile application,
the TicketID will be created by line leader that press the button. However, line
leader is not required to login to press the button.

The action for assign TicketID, accept TicketID, and ignore TicketID will requires
the actors to login then those use case are included to login. Furthermore, leader is
also able to accept the TicketID. However, the mechanic leader is the only one
who is able to assign TicketID.

Figure 4.16 shows the use case diagram of website. There are 2 actors, layout
leader and stakeholders. All use case is included into login use case. Layout leader
is able to input the layout changeover schedule, generate summary, inspect the
TicketID status, and see the status of drawing and machine quantity. On the other
side, stakeholders are able to observe and inspect for general dashboard, line
dashboard, machine dashboard, and manpower dashboard as their reference to
decision making. On the implementation, the dashboard can be seen by all of the
user and stakeholder. For layout menu, layout leader is the only one who is able to
interact with.

On website, the actor only can login, they cannot register. Registration is only on
mobile application. Layout leader is required to login to input the layout
changeover schedule, generate summary, inspect the TicketID status, and see the
status of drawing and machine quantity. Stakeholders also required to login to
observe and inspect for general dashboard, line dashboard, machine dashboard,
and manpower dashboard. That is the reason of include relation to login.

57
 Figure 4.16 Use Case Diagram of Website

4.3.4 System Flow Chart

Based on the system architectures and use case diagram, the flow chart for the
system can be made. Start for the security requirements, machine problem menu,
and layout changeover menu. Figure 4.17 shows the flow chart of the security
system.

Security system of mobile application consists of the sign-up and sign-in as the
boundaries of the system with unauthorized people. There are user database that is
hold all of user information. The following list is the requirements of creating the
new system:
1. Full name.
2. KPK (Employee ID).
3. PT TMC Email Address.

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 Figure 4.17 Security System of Mobile Application

After registration, there is sign-in session and input the PIN. After that, the mobile
application will display the home screen.

On the other side, there is also flow chart for machine problem menu. Figure 4.18
shows the machine problem flow chart of mobile application. The flow starts
when the line leader press red button, then the red light will be on. Right after,
TicketID for machine problem will be created and notification will be released.
The mechanic can take the TicketID by clicking on the notification or through
home screen. Besides that, the mechanic leader is able to assign the TicketID to
certain mechanic personnel. After that, there will be a confirmation pop-up for the
mechanic. This is important since the mechanic only can take 1 TicketID at one
time. If the mechanic accept the TicketID, then mechanic can go to the location
and press red button. Input MachineID is able by type or scan machine barcode.

59
Then start repairment and the data will be transferred to machine problem and
machine changeover. Start from the TicketID created until the mechanic start the
repairment, it will be counted as response time.

60
 Figure 4.18 Machine Problem of Mobile Application

On certain condition, mechanic can call a friend if the work cannot be done only
by one mechanic. The notification will be released and the other mechanic is able
to accept the TicketID as a second mechanic. If the mechanic is not call a friend,
then the menu of semi-finish will be shown. After the repairment process, then
mechanic can choose the machine downtime reason. After that, close the
TicketID.

Figure 4.19 shows the layout changeover flowcart. There are 2 differents start
point which are for the planned changeover and unplanned changeover. For the
planned changeover, layout leader will input the layout changeover schedule
through website, then the TicketID created. This TicketID will be stored to layout
changeover database. On the mobile app, mechanic personnel can see the
TicketID available and see the summary of the TicketID. The mechanic can select
the TicketID. If the layout personnel confirm to accept the TicketID, the toy
number, layout drawing, and machine quantity are displayed. Those informations
come from IE New Toy Tracker database. After that, the layout personnel can
perform manual operation of layout. If finished, then they need to input
MachineID used by scan machine’s barcode or type the MachineID. Then the
conficmation pop-up shown to ensure all machine has been scanned. Now, the
TicketID is able to be closed.

On the other side, for unplanned changeover, the line leader needs to press yellow
button and the layout personel can accept the TicketID. The different is only that
the layout personnel needs to input the work order detail of the changeover.

61
Figure 4.19 Layout Changeover Flow Chart

62
4.3.4 Technology Stack
Technology stack in smart factory refers to the technology utilized in the
implementation. The main components of technology stack in smart factory
consists of hardware, software, and communication protocol.

4.3.4.1 Hardware
Hardware refers to the tangible assets that are being utilized. The utilization of
hardware can be identified by analyzing the system architecture. Figure 4.14
shows the system architecture for the smart factory. Based on the system
architecture, there are hardwares being utilized as follow:
1. Andon Button.
2. IoT Box.
3. Computer.
4. Smart Phone.
5. Smart Phone Tablet.
6. Monitor Display 50 Inch.

The detailed specification can be seen on Table 4.4. Table 4.4 shows the
specification for main hardware.
Table 4.4 Device Specification

Device Specification

Andon Button

IoT Box Microcontroller ESP8266

Computer

Smart Phone Honeywell EDA51K

Smart Phone Tablet Microsoft Surface Pro 6 i5 128GB

Monitor Display 50 Inch UA50 BU8000

Besides the hardware being identified by analyzing the system architecture, there
are several hardware being used to support those hardware, such as:
1. Push Button with LED Red.
2. Push Button with LED Yellow.

63
 3. Push Button with LED Green.
4. Push Button with LED Blue.
5. Panel Electric Tibox.
6. Others.

The detailed specification can be seen on Table 4.5. Table 4.5 shows the
specification for supporting hardware.

Table 4.5 Device Specification

Device Specification

Push Button with LED Red HY-TN-220-4/PRM-420-RYGB

Push Button with LED Yellow HY-TN-220-4/PRM-420-RYGB

Push Button with LED Green HY-TN-220-4/PRM-420-RYGB

Push Button with LED Blue HY-TN-220-4/PRM-420-RYGB

Panel Electric Tibox Tibox 150x250x100

4.3.4.2 Software
Software refers to the intangible assets that are being utilized. The utilization of
software can be identified by analyzing the system architecture. Figure 4.14
shows the system architecture for the smart factory. Based on the system
architecture, there are softwares being utilized as follow:
1. Local Server.
2. PT TMC Database.
3. Mobile Application.
4. Website.

4.3.4.3 Generic IoT Architecture

Generic IoT architecture refers to the IoT framework that is based on the
requirements of the application, network, service model, and protocols business.
There is no standard reference about generic IoT architecture. This research
applies elementary IoT structure that consist of 3 layers model. There are
application layer, network layer, and perception layer.

64
Perception layer refers to the physical and concrete devices that become
cornerstone of IoT technology that has the objective to collect the information and
transform the information into a digital signal and transmit the signal to the next
layer, in this case is network layer. The physical devices includes sensors
(illumination, humidity, and temperature), RFID, and actuators (mechanical,
electrical, and hydraulic). In this research, the perception layer used is andon
button that connected to IoT box. Figure 4.20 shows the component and drawing
of IoT box.

Figure 4.20 Peception Layer

The second is transmission layer that is refered to the communication channel of

perception layer and application layer. In the implementation, there are 2
alternatives, wireless protocols and wired protocols. Wireless and wired has their
own advantages and disadvantages. Wireless protocols has flexibility, scalability,
and easy installation. Meanwhile for wired protocols has security, speed, and
performance. On this research, the implementation using wireless and wired
transmission layer. There are parts on system architecture that will be connected
using wireless protocol and wired protocol. The last is application layer where the
data transferred by transmission layer being received. This data shown in the
application and the user will take an action. By the application layer, real-time
monitoring and also data-driven decision can be made.

4.3.4.3 Communication Protocol

Communication protocol refers to the method of devices connected to each other.
In the communication protocols, there are application layer, transport layer, and

65
network layer. Table 4.6 shows the layers and example for communication
protocols.
Table 4.6 Communication Protocols

No. Layer Example

1 Application MQTT, QoAP, REST, XMPP, and AMQP.

TCP, UDP, DCPP, SCTP, RSVP, TLS, DTLS, RPL,
2 Transport CARP, CORPL, QUIC, uIP, Aeron, CCN, NanoIP,
and TSMP.

3 Network WiFi, Bluetooth, ZigBee, Z-Wave, and LoRaWAN.

In the implementation, the application layer used is MQTT (Message Queuing

Telemetry Transport) since MQTT provides low bandwidth usage and low power
consumption. MQTT is used to connect the IoT Box and EDGE PC. Besides that,
MQTT as a messaging protocols that has objectives for publish and subscribe
model provide advantages such as lightweight and easy to implement. MQTT also
can be categorized as open standard because MQTT can be used to numerous
hardware and software. Even on the confidential information, MQTT also provide
advanced security services to ensure the secutiry of the information. More over,
MQTT also provide the scalability (support numerous of devices) and reliability
(message persistence and management).

On the transport layer, TCP is used as a transmission control protocol to connect

the Edge PC and PT TMC Server. TCP is used since TCP provide advantages
such as reliability, flow control, reliability, error-checking, flow control, and
connection-oriented. Meanwhile for the network, WiFi is used to connect the
mobile application and website ti PT TMC Server. Figure 4.21 shows the
Communication Protocols. In conclusion of communication protocols used, the
following list describe it:
1. Wired cable is used to connec andon button and IoT box.
2. MQTT is used to connect IoT box and EDGE PC.
3. TCP/IP is used to connect EDGE PC and PT TMC server.
4. WiFi is used to connect PT TMC Server and Website and Mobile
Application,

66
 Figure 4.21 Communication Protocols

4.3.4.5 Security Concerns

Security concern focused on the application layer of generic IoT structure based
on the requirement from IT Department of PT TMC. Figure 4.22 shows the
security concern on application layer. There are requirements of device
connection. Connection device listed below:
1. IoT Devices Andon Lamp and IoT Box MQTT Client.
2. IoT Box MQTT Client and EDGE Pooling MQTT Broker.
3. EDGE Pooling MQTT Broker and EDGE Pooling MQTT Publisher.
4. EDGE Pooling MQTT Publisher and PT TMC Server.

67
 Figure 4.22 Application Layer Security

4.3.5 User Interface Design

The user interface design is made based on numerous methodologies available
such as user-centered design and human-centered design. User-centered design
refers to the methodologies of designing an user interface based on the user
requirements. While for human-centered design refers to the design of user
interface that are understand the behaviour of the user. User requirements has
been explained previously in order to support user-centered design. For the
human-centered design, the explanation below explain the findings of behaviour
from the users.
1. Mechanic team:
a. Often to collaborate with partner (2 mechanics) to repair 1 machine
problem.
b. Often to type the same machine downtime category with different
sentences.

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2. Layout leader:
a. Shift hours refers to Table 4.1.
Table 4.7 Shift Hours

Date Shift Time

03/15/2023 1 22:30:01 (03/14/2023) – 07:10:00
(03/15/2023)
03/15/2023 2 07:10:01 – 15:40:00
03/15/2023 3 15:40:01 - 22:30:00
03/16/2023 1 22:30:01 (03/15/2023) – 07:10:00
(03/16/2023)
03/16/2023 2 07:10:01 – 15:40:00

b. Often to collaborate with partner (2 technicians) to layout 1 line.

c. Layout changeover summary interpretation. Figure 4.16 shows
how Layout Leader make a summary of layout changeover.

69
 Figure 4.16 Layout Changeover Summary

There are 2 layout times:

If the layout schedule is for Morning
RunSch = 2
PrepSch = 2
If the layout schedule is for Afternoon
RunSch = 1 next day
PrepSch = 3
This explanation will be the guideline on designing an user interface for layout
leader that has responsibility to make a layout changeover summary. The system
developed will have the same flow and logic as the current system.

70
 Figure 4.17 Layout Changeover 1

Figure 4.17 shows the first - third cases of the interpretation of layout changeover
summary. There are 5 cases to describe the interpretation. The gantt chart of the
interpretation can be seen on figure.

Figure 4.18 Layout Changeover 2

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Figure 4.18 shows the forth case of the interpretation of layout changeover
summary. The gantt chart of the interpretation can be seen on figure.

Figure 4.19 Layout Changeover 3

Figure 4.19 shows the fifth case of the interpretation of layout changeover
summary. The gantt chart of the interpretation can be seen on figure.

After applying user-centered design and human-centered design, the user interface
can be made. In this research, the user interface was made on Figma including
these following aspects:
1. Design.
2. Flow.
3. Prototype.

After understanding the user requirements and behaviour, the user interface can ba
developed. There are 2 system used on the smart factory that being developed,
mobile application and website. Figure 4.20 shows the mobile application user
interface. Mobile application support the dynamic workflow of mechanic team
and layout team. Mobile application consists of 4 main menu which are machine
problem menu, layout changeover menu, user menu, and setting menu. Appendix

72
1 shows and describe the features and function on mobile application’s user
interface.

Figure 4.20 User Interface of Mobile Application

Figure 4.21 shows the user interface of website. This website is being displayed
on packout mechanic modul and being inspected by stakeholders. The objective of
the dashboard is to show the analyzed data to make a decision. For example, the
mechanic leader is able to balance the workload of mechanic by assigning certain
mechanic to a TicketID.

73
 Figure 4.21 User Interface of Website

Figure 4.22 Layout Changeover Menu on Website

There is layout changeover menu on website that specifically only can be

accessed by layout leader. This menu will provide the layout leader with user-
friendly environment to input layout changeover schedule. By this menu also,
layout leader can monitor TicketID of layout changeover status. This menu also

74
connected with IE New Toy Tracker as the layout drawing and machine quantity
provider. Appendix 2 shows and describe the function of website.

4.3.6 Data Requirement

Based on user requirements, stakeholder requirements, unified modeling
language, and system flow chart, data requirement is able to be summarized.
Table 4.8 shows the data requirement. In the data requirement, there are 6 actors
related and directly use the system, mechanic leader, layout leader, mechanic
personnel, layout personnel, senior of tooling engineer, and stakeholders. Since
the system hold numerous data, then the data requirements can be analyzed and
listed by categorizing by the menu on the system. There are security section,
overall machine problem menu, layout changeover menu, user menu, and
dashboard. There are 64 data that are required in the system. The data also can be
categorized by its status. Unrefined data refers to the raw data and Derived data
refers to the processed data through certain calculation.
Table 4.8 Data Requirement
Menu Actor Data Name Data Status
Full name Unrefined data
KPK Unrefined data
Security Email address Unrefined data
section on
All actor Phone number Unrefined data
application and
website Password Unrefined data
PIN Unrefined data
Position Unrefined data
TicketID Derived Data
Location Unrefined data
MachineID Derived Data
Machine Name Unrefined data
Report Time Unrefined data
StartTicketID_01 Unrefined data
Overall Mechanic leader MechanicID_01 (KPK) Unrefined data
Machine and mechanic
MechanicName_01 Unrefined data
problem personnel
Call A Friend Unrefined data
FinishTicketID_01 Unrefined data
SemiFinishTicketID_01 Unrefined data
MechanicID_02 (KPK) Unrefined data
MechanicName_02 Unrefined data
StartTicketID_02 Unrefined data

75
 Menu Actor Data Name Data Status
FinishTicketID_02 Unrefined data
Downtime Cause Unrefined data
Downtime Detail Unrefined data
TicketID Unrefined data
Current Date Unrefined data
WE of CurrentDate Unrefined data
Schedule Date Unrefined data
Run Shift Unrefined data
Preparation Date Unrefined data
Preparation Shift Unrefined data
Layout Toy Number Unrefined data
changeover on Layout leader and Line Number Unrefined data
application and layout personnel Remarks Unrefined data
website
Status Derived Data
TechnicianID_01
Unrefined data
(KPK)
TechnicianID_02
Unrefined data
(KPK)
Start Time Unrefined data
Finish Time Unrefined data
MachineID Unrefined data
XP Level Derived Data
User All actor Productivity Derived Data
KPI Derived Data
Percentage of line
Derived Data
availability.
Line utilization. Derived Data
24-hours trend of
Derived Data
downtime.
Top 5 machine
Derived Data
downtime.
Top 5 Line downtime. Derived Data
Dashboard on Top 5 slowest repair
Stakeholders Derived Data
website time by line (sum).
Top 5 slowest response
Derived Data
time by line (sum).
Top 5 slowest repair
Derived Data
time by line (average).
Top 5 slowest response
Derived Data
time by line (average).
24-hours trend of
Derived Data
response time.

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 Menu Actor Data Name Data Status
24-hours trend of repair
Derived Data
time.
Line Status Derived Data
Top 5 problematic
machine – Total of Derived Data
downtime.
Top 5 problematic
machine – Average of Derived Data
downtime.
Top 5 slowest response
Derived Data
time by machine.
Top 5 slowest repair
time by downtime Derived Data
reason.
Total layout
Derived Data
changeover trend.
Total layout
Derived Data
changeover by shift
Total layout
Derived Data
changeover by line.
Total layout
Derived Data
changeover duration.
Layout changeover
Derived Data
duration by line.

4.3.7 Data Flow

Data flow diagram is a diagram that visualize the flow of the data on the system.
Data flow diagram is commonly used in the system analysis and software
development. Data flow diagram typically consist of context level diagram, data
flow diagram level 0, and data flow diagram level 1.

Context level diagram of data flow diagram is the highest level of data flow in the
system to describe and visualize the interation between external entities (actors)
and the system. There is an output and input that will be interacted between
thexternal entities and the system. Figure 4.23 shows the context level diagram of
data flow diagram.

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 Figure 4.23 Context Level Diagram

There are 7 entities in the context level diagram, mechanic personnel, layout
personnel, line leader, stakeholders, mechanic leader, senior tooling of engineer,
and layout leader. Line leader will release a TicketID to the system. As a user in
the system, mechanic personnel, layout personnel, stakeholders, mechanic leader,
and layout leader are required to logged in and if the account is new, then the
senior of tooling engineer will verified the account data. Mechanic team work on
the TicketID released by line leader and they need to store numerous data to the
system to close the ticket. While for layout team, the TicketID can be released by
layout leader or line leader. All of the data is shown on Figure 4.23.

4.4 Development

Development is the third stage of ADDIE methodology. Development stage focus

on the user manual, setting up the technology infrastructure, and preventive
maintenance model development.

4.4.1 User Manual

4.4.2 Setting Up the Technology Infrastructure

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4.4.3 Preventive Maintenance Model Development
As the data collection of machine repairment on packout shiftly report that has
9882 data about machine downtime from January 28th, 2022 – March 3rd, 2023,
the prevenrive model focused on the most problematic machine type that requires
special attention. The indications are the highest duration of downtime and the
highest frequency of downtime. Data collection was summarized using Microsoft
Excel and Minitab in order to analyze the pattern of the data.

Figure 4.40 shows the downtime frequency of machine type utilized on packout
area. Based on the pareto chart, sealing blister has the highest downtime
frequency which covers 54.8% of downtime frequency with the number of
downtime 5410 times. The other machine types has percentage of downtime
frequency below 10%. It can be concluded that sealing blister requires special
attention in the aspect of downtime frequency.

Figure 4.40 Pareto Chart of Downtime Frequency

Figure 4.41 shows the accumulation of downtime of machine type utilized on

packout area. Based on pareto chart, sealing blister has the highest accumulation
of downtime with 113899 minutes that covers 48% of the accumulation of
downtime.The other machine type has percentage of accumulation of downtime

79
below 15%. It can be concluded that sealing blister requires special attention in
the aspect of downtime accumulation duration.

Figure 4.41 Pareto Chart of Accumulation of Downtime

Based on the result of the analysis of downtime frequency and the accumulation
of downtime using pareto chart, the conclusion is sealing blister is the most
problematic machine with the highest number of downtime frequency and
accumulation of downtime. The preventive maintenance model developed for
only sealing blister.

The next step is to calculate the MTBF and MTTR for sealing blister. The MTBF
and MTTR calculated by considering the distribution and scale of the data. In
order to perform those, Minitab is used. The data were filtered based on the
machine type and the Machine ID 31 since this machine has the highest frequency
of downtime.

Figure 4.42 shows the probability plot for TTR. The closest distribution value to 1
means the stronger the relationship. Figure 4.42 shows the value of the
distribution for 4 types of distribution. The data needs to be aalyzed more using
distribution overview plot to determine the distribution type.

80
 Figure 4.42 Probability Plot for TTR

The scale is required in order to calculate the MTTR. The scale can be calculated
using Distribution Overview Plot on Minitab. Figure 4.43 shows the distribution
overview plot of Weibull that contains the shape and the scale. Based on the
figure, the shape is 1.30885 and the scale (θ ¿ is 18.7990.

Figure 4.43 Distribution Overview Plot

81
Since the shape and scale are known by the distribution plot overview, then
MTTR can be calculated using Equation (4-5).
θ∗(β−1)
MTTR=
β
(4-5)
18.779∗( 1.30885−1 )
MTTR= =4.43129 minutes
1.30885

Based on the calculation, the MTTR for sealing blister is 4.43 minutes.

Figure 4.44 Probability Plot for TBF

Figure 4.42 shows the probability plot for TBF. The closest distribution value to 1
means the stronger the relationship. Figure 4.44 shows the value of the
distribution for 4 types of distribution. The data needs to be aalyzed more using
distribution overview plot to determine the distribution type.

The scale is required in order to calculate the MTBF. The scale can be calculated
using Distribution Overview Plot on Minitab. Figure 4.45 shows the distribution
overview plot of Weibull that contains the shape and the scale. Based on the
figure, the shape is 0.71746 and the scale (θ ¿ is 48.2032.

82
 Figure 4.45 Distribution Overview Plot for TBF

Since the shape and scale are known by the distribution plot overview, then
MTBF can be calculated using Equation (4-6).
1
MTBF=θ∗Г (1+ )
β
(4-6)

MTBF=48.2032∗Г 1+ ( 1
0.71746 )
=59.63 hours

Based on the calculation, the MTBF for sealing blister is 59.63 hours. However,
MTBF also can be calculated using Equation (4-7).

MTBF=θ∗exp ⁡(β∗ln ( 2 ) )
(4-7)

MTBF=48.2032∗exp ( 0.71746∗ln (2 ) )=79.25 hours

Since the Equation (4-7) give the more reasonable result. Then, the result of
MTBF is 79.25 hours or 3.3 days. The packout shiftly report analysis on the
beginning of this chapter mention that the preventive maintenance will focus on
shift 1 to improve the productivity of mechanics on shift 3. With that

83
consideration, the preventive maintenance for sealing blister is rounded up to 4
days as the time interval between preventive maintenance.

4.5 Implementation

4.5.1 User Briefing and Training

4.5.2 Piloting Implementation

4.6 Evaluation

4.6.1 User Acceptance Test

4.6.2 Feedback Analysis

4.7 ADDIE Methodology Loop

4.7.1 Analysis Stage Review

4.7.2 Design Stage Review
4.7.3 Development Stage Review
4.7.4 Implementation Stage Review
4.7.5 Evaluation Stage Review

4.8 Advantages of Smart Factory Implementation

4.8.1 Main Advantages

4.8.1.1 Response Time of Machine Downtime Reduction

4.8.1.2 Layout Changeover Duration Reduction

4.8.2 Side Advantages

4.8.2.1 Activity Tracking of Manpower

4.8.2.2 Loading Distribution for Leader

4.8.2.3 Manpower Productivity Improvement

84
4.8.2.4 Collect Data for Repair Time Standarization

4.8.2.5 Developing Centered Database

4.8.2.6 Preventive Maintenance

4.8.2.7 Performance Appraisal

Input the mechanicsm of XP productivity etc.

4.9 Investment and Cost Savings

4.9.1 Investment Calculation

No
Category Description Price Quantity Total Price (IDR)
.
Android Mobile IDR
1 Software App and 60,000,00 1 IDR 60,000,000
Websites 0
IoT Box (IoT
IDR
2 Device 120 IDR 144,000,000
1,200,000
Controller)
Push button with IDR
3 120 IDR 9,000,000
LED Red 75,000
Push button with IDR
4 120 IDR 9,000,000
LED Yellow 75,000
Push button with IDR
5 120 IDR 9,000,000
LED Green 75,000
Push button with IDR
6 120 IDR 9,000,000
LED Blue 75,000
Power Supply IDR
7 120 IDR 36,000,000
Hardware Meanwell 300,000
and Panel Electric IDR
8 120 IDR 33,000,000
Electrical Tibox 275,000
Power Cable (3 IDR
9 720 IDR 11,520,000
core 1.5mm) 16,000
Power Cable (5 IDR
10 600 IDR 15,000,000
core 0.75mm) 25,000
IDR
11 Andon Lamps 120 IDR 53,160,000
443,000
Supporting part
IDR
12 (Conduit, Clamp, 1 IDR 6,000,000
6,000,000
Ties Cable, etc)
IDR
Electrical and IoT
13 80,000,00 1 IDR 80,000,000
Box installation
0
14 IT Acess Point IDR 5 IDR 104,690,000

85
 20,938,00
0
IDR
Work Station
15 51,634,50 1 IDR 51,634,500
Edge PC
0
Rackmount
IDR
16 IR8020P - 20U + 1 IDR 8,000,000
8,000,000
FS80
Monitorin TV SAMSUNG IDR
17 1 IDR 8,500,000
g 50 Inch 8,500,000
Industrial IDR
18 Android Phone 11,300,00 3 IDR 33,900,000
Honeywell 0
Smart watch for IDR
19 Devices 6 IDR 2,434,800
notification 405,800
Microsoft IDR
20 Surface Pro 6 i5 13,100,00 1 IDR 13,100,000
128GB 0
IDR
Total Amount
696,939,300.00

4.9.2 Cost Savings Calculation

4.9.3 Break Even Point Calculation

86
 CHAPTER V
CONCLUSION AND RECOMMENDATION

5.1 Conclusion

5.2 Recommendation

87
REFERENCES

88
 APPENDIX I
USER INTERFACE OF MOBILE APPLICATION

1. Welcoming Screen 2. Sign-in or Sign-Up

3. Language Setting 4. Sign-In Page

5. Sign-Up Page 6. PIN Verification

89
 7. Forgor Password Page 8. Forgot PIN Page

9. Home Screen 10. Home Screen Notification

11. Overall Machine Problem 12. Notification

90
13. TicketID Information 14. Confirmation Pop-Up

15. Input Machine Detail 16. Repair Machine Progress

17. Finish Option 18. Machine Problem Detail

19. Layout Menu 20. Layout Ticket

91
 21. Forgot PIN Page 22. Confirmation Pop-Up

23. Partner Selection 24. Changeover Detail

25. Scan Barcode Machine 26. Close Ticket Confirmation

92
27. Layout WO Notification 28. Work Order Detail

29. Profile Menu 30. Edit Profile

31. Productivity 32. History Detail

93
33. Setting Menu 34. Change Password

35. Change PIN 36. Success

94
 APPENDIX II
USER INTERFACE OF WEBSITE

General - Dashboard

95
Line - Dashboard

96
Machine Problem – Dashboard

97
Manpower – Dashboard

98
Input Layout Changeover

Changeover Summary

99
Ticket Status

Drawing and Machine

100
APPENDIX III
USER MANUAL

101
 APPENDIX IV
CODE OF PREVENTIVE MAINTENANCE

102