STANDARDIZATION OF EFFECTIVE PRODUCTION SCHEDULING IN PHARMACEUTICAL INDUSTRY Febrian Isharyadi and Desinta Rahayu Ningtyas Research and Development

BSN and Lecturer assistant Pancasila University Email: febrianisharyadi@yahoo.co.id, de.cinta48@gmail.com

Abstract Indonesia is a big country which has many population. However, based on data from the United Nations of Development Programme 2012 (UNDP), Indonesia included low levels of health. Based on these data led to the market demand for drugs will be more and more, especially in Indonesia. To meet the demand, pharmaceutical industry should have a way to maximize its production facility that can produce optimal drugs. One of system to support optimalize production is the process of scheduling, one of them is on a production machine, especially for a pharmaceutical company that produces more than one type of drug. Standardization of the scheduling process in production process is needed so that the production process to be efficient in terms of production costs and production time on an ongoing basis and sustainable. This study was done by comparison of 5 tablets dosage drug products with different types produced in a pharmaceutical industry. Data processing using software MS Project 2007 with a comparison of 3 methods namely algorithm Least Slack algorithm, SPT (Short Processing Time) and Johnson.Criteria are compared to determine the effectiveness of the production of the% efficiency of the engine, minimizing the makespan and minimizing slack. Where then the results were analyzed using the software Analytic Hierarchy Process (AHP). Result of this study from calculate Least Slack algorithm approach, SPT and Johnson with the help of software Microsoft Project 2007, which gives the value of the highest engine efficiency and is Least Slack algorithm, gives the minimum makespan value is SPT, while Johnson algorithm gives the total slack lowest. And SPT algorithm can be used as a standard in making a scheduling method to obtain the optimal production process. Keyword: Scheduling, Least Lack Algorithm, SPT Algorithm, Johnson Algorithm, Analytical Hierarchy Process

I.

INTRODUCTION

Indonesia is a big country which has many population, nowadays Indonesia has 237.641.326 people (Statistics Indonesia, 2012). With this population Indonesia is one of big five countries which have a lot of people. However, based on data from the United Nations of Development Programme 2012 (UNDP), Indonesia included low levels of health with the amount of human life expectancy in Indonesia is 69.8 years and the mother of safety level of 100,000 births were 350 mothers die in childbirth (UNDP, 2012). And based on Statistics Indonesia data visible downward trend in the level of health of the population in Indonesia in terms of the number of people seeking went away treatment from disease (see figure 1)

Figure 1. Graphic of average people seeking treatment went away from hospital per month 2007 - 2011 (source : Statistics Indonesia, 2012) Based on these data led to the market demand for drugs will be more and more, especially in Indonesia. To meet the demand, pharmaceutical industry should have a way to maximize its production facility that can produce optimal drugs. Optimal of drug productionpharmaceuticals on an industry depends of several factors among others is of resources material, machine and humans, a process has a limitations time, both time process is and the target is completed process (due date). One of system to support optimalize production is the process of scheduling, one of them is on a production machine, especially for a pharmaceutical company that produces more than one type of drug. Of the many products that are required and the limited facilities owned, it needs to make a good scheduling system so that each facility and the components involved in the production process can be run effectively and generate optimal production output. Standardization of the scheduling

process in production process is needed so that the production process to be efficient in terms of production costs and production time on an ongoing basis and sustainable. With this study are expected to be obtained by an appropriate method to be used as a standard in the scheduling process in the production process in the pharmaceutical industry

II. 2.1.

THEORY Scheduling

Scheduling is the allocation of resources overtime to perform collection of risk, that mean scheduling is the allocation of limited resources to work on a number of jobs (Ginting, 2009). Scheduling prepared taking into account the various constraints that exist. Good scheduling will have a positive impact, namely the low operating costs and delivery time, which can ultimately improve customer satisfaction. Bedworth (1987) identified several objectives of the activity scheduling as follow: 1. Improve resource use or reduce waiting time, so that the total processing time can be reduced and productivity can be increased. 2. Reducing inventories of semi-finished goods or reduce the number of jobs waiting in the queue when the available resources are still working on other tasks. Baker said that if the theory of a schedule of work flow is constant, the flow queues that reduce the average flow time would reduce the average inventory of semi-finished goods. 3. Reduce some delays on job completion deadline has thus minimizing penalty cost (delay). 4. Assist decision-making on planning plant capacity and type of capacity required so that additional costs can be avoided. (Ginting, 2009) In general, the production process can be described as follows:
5.
- Material 6. 7. 8.Machine Man Management Method Input Dispensing Sieving Mixing Granulating Drying Tabletting - Primary Packaging - Secondary Packaging - Finished Goods

9. 10. Gambar 1. Diagram Proses Produksi

Process Output

Figure 2. Production process diagram

Several criteria can be used to determine the effectiveness of a scheduling process are:

1.

Processing Time (ti) Is the time it takes to do a job (i). Within this process has included the time required for preparation and setting (set-up) throughout the process.

2.

Due-date (at) Is a time limit in which the last operation of a job (i) have completed (the date the job was promised to the customer). Complete the work after the due date are allowed, but then will hit penalty. Due date should refer to deadlines.

3.

Slack Time (SLi) Is the remaining time arising from the time the process is smaller than its due-date.

SLi = d i ti ..................................................................................
4.
Flow Time (Fi)

(1)

Flow time, the time span between the point where the job is available for processing at a point when the task is completed. So the flow time with processing time added up to the time when the task wait before being processed. Flow time is expressed by (Fi).

5.

Completion Time (Ci) Is the time required to complete the work started from the current availability of jobs (t

= 0) until the work is completed.

6.

Lateness (Li) Is the difference between the completion time (Ci) with its due-date (on). lateness of

a job has a positive value when the job is completed after its due-date. Conversely, if the work is completed after the deadline, the work will have a negative delay.

7.

Tardiness (Ti) Time is a measure of late which is positive if the work can be completed more quickly

than its due-date, the work will have a negative delay. Conversely, if the work is completed after the deadline, the work has a positive delay. Tardiness, the size of the positive lateness.

If the job is completed quickly, it will have a negative lateness but tardiness = 0. If the task has a positive lateness, it will have a positive tardiness as well. Tardiness expressed by Ti where Ti is the maximum of {0, Li}.

8.

Makespan (M) Is the total completion time of jobs ranging from the first sequence is done on a

machine or work center to sequence the first to the last job on a machine or work center last. Minimum makespan usually indicates better utilization of machines (Pinedo, 2008)

9.

Heuristic A problem resolution procedures or rules of thumb (rule of thumb) that was shown to

produce

good

results

but

does

not

guarantee

optimal

results.

(Source: Ginting, 2009) In addition, the criteria for measuring the performance and optimization of scheduling is as follows: a. Fair (fairness) Processes are treated equally, that gets a pemrosesyang same time and no one who did not get the service processor so that the shortage of time. b. Efficiency (eficiency) Efficiency is calculated by processing or utilization ratio (ratio) processors busy time. c. Response time (response time)

2.2.

Analytical Hierarchy Process (AHP) The decision making process is basically selecting an alternative. The main

equipment Analytic Hierarchy Process (AHP) is a functional hierarchy with the main input of human perception. With the hierarchy, a complex and unstructured problems solved in groups. Then group-the group are arranged become an form of hierarchy (Permadi,1992). One purpose of a general nature can be described in some more detailed sub-goals that can explain what is meant in the first goal. This description can be carried on until finally obtained objective of an operational nature. And at the lowest hierarchy is done the process

of evaluating the alternatives, which is a measure of the achievement of the main objective, and at the lowest hierarchy can be specified in units of what criteria are measured. Analytic Hierarchy Process (AHP) can solve the problem of multicriteria complex into a hierarchy. Complex problems can be interpreted that the criteria of a problem that so many (multi-criteria), the structure of the problem is unclear, uncertainty opinions of decisionmakers, decision-makers more than one person, and the inaccuracy of available data. According to Saaty, the hierarchy is defined as a representation of a complex problem in a multi-level structure where the first level is the goal, which was followed-level factors, criteria, sub-criteria, and so on down to the last level of the alternatives. With the hierarchy, a complex problem can be decomposed into their groups are then arranged into a hierarchy so that the problem will appear more structured and systematic.

III.

METHODS

This study was done by comparison of 5 tablets dosage drug products with different types produced in a pharmaceutical industry. Data processing using software MS Project 2007 with a comparison of 3 methods namely algorithm Least Slack algorithm, SPT (Short Processing Time) and Johnson. Criteria are compared to determine the effectiveness of the production of the% efficiency of the engine, minimizing the makespan and minimizing slack. Where then the results were analyzed using the software Analytic Hierarchy Process (AHP) in order to obtain an effective method in determining the scheduling of the production process.

IV. 4.1.

RESULT Data

Subjects analyzed were stage work on 5 types of medicinal products (A, B, C, D, and E) with different types. The order of the five stages of the work of these products are as follows: 1. Granulation process. 2. Drying process 3. Tabletting process. 4. Coating process.

5. Filling Prooses. 6. Labelling process.

Data on the availability of production machinery and processing time at each stage, are as follows: Table 1. Availability of machines at one of the pharmaceutical industry Production Process Granulation Process Drying Process Tabletting Process Coating Process Filling Process Number of Machine 2 1 4 1 1

Table 2. Time per stage of the production process of each work product
Product Quantity
Operation

100000 tablet

100000 tablet

100000 tablet

100000 tablet

100000 tablet

Granulasi Tabletting Filling Labelling Granulasi Tabletting Coating Filling Labelling Granulasi Tabletting Filling Labelling Granulasi Tabletting Coating Filling Labelling Granulasi Tabletting Filling Labelling

Production Machine 2 3 4 5 6 7 8

Time Process 11.6 1 11.6 12.4 1.8 1.13 5.8 12 12.4 1 4.1 18.1 11.3 1 2 4 1 0.5 11.5 3.3 24 5

Table caption: 1. Machines used for each production steps, the process: a. Source 1: Machines Fluid Bed Granulator. b. Source 2: Machine Blender. c. Sources 3: granulator machine. d. Sources 4: Drying Machine. e. Sources 5: Machine Tabletting 1. f. Sources 6: Coating Machine. g. Sources 7: Filling Machine Tablet.

h. Sources 8: Labelling Machines. 2. mark indicates the stage of the process (j), (i) done using machine (h). 3. Due date specified in this study was for 20 days 4.2. Results

Based on data production time per stage work after analysis using MS Project are as follows: 4.2.1. Efficiency Comparison Engine Engine efficiency is obtained according to the result of processing using Least Slack algorithm, SPT (Short Processing Time) and Johnson are as follows: Table 3. Engine efficiency least slack scheduling algorithms
Machine Mesin Mesin Mesin Mesin Mesin 1 2 3 Granulasi 26.9 8h 8h 8h Tabletting 1 11.53 3.3h 0.9h Coating 9.8 Filling Tablet 66.7 1.2h 8h Labelling 41.6 Work Days 4 5 6 7 8 9 10 11 12 2.9h 7.33h 2.67h 7.13h 8h 8h 8h 8h 8h 8h 8h 1.5h 1.2h 3.8h 5.6h 6.8h 3.5h 7.8h 7.5h 5.4h Total Hours 32 24 16 80 64
%Efficiency

84.06 48.04 61.25 83.38 65.00

68.35

Average

Table 4. Engine efficiency SPT scheduling algorithm

Machine Mesin Granulasi Mesin Tabletting 1 Mesin Coating Mesin Filling Tablet Mesin Labelling
Average

1 26.9 8h 11.53 7h 9.8 5h 66.7 1h 41.6

Work

Days 3 4 5 6 7 8 9 10 8h 8h 2.9h 0.83h 0.4h 3.3h 4.8h 3.2h 8h 8h 8h 8h 8h 8h 8h 6.5h 0.5h 7.2h 5.2h 5.1h 7.7h 8h 2.9h 1.5h 3.5h 2

Total Hours 32 32 16 80 81

%Efficiency 84.06 36.03 61.25 83.38 51.36

63.22

Table 5. Engine efficiency Johnson scheduling algorithm

Machine Mesin Granulasi Mesin Tabletting 1 Mesin Coating Mesin Filling Tablet Mesin Labelling
Average

1 2 3 26.9 8h 8h 8h 11.53 6.1h 2.5h 0.8h 9.8 4h 66.7 1h 8h 8h 0.5h 41.6

Work

Days 4 5 6 7 8 9 10 2.9h 2.13h 3.97h 1.83h 8h 8h 8h 8h 8h 8h 1.7h 5.9h 5.4h 5h 2.3h 8h 8h 6.5h

Total Hours 32 32 24 80 64

%Efficienc y 84.06 36.03 40.83 83.38 65.00

61.86

Chart comparison of the efficiency of the algorithm used machine can be seen in figure 2 below

Figure 3. Chart comparison of the efficiency of the algorithm From the above chart can be seen, Least Slack algorithm gives the highest efficiency for each machine. 4.2.2. Minimization of makespan comparisons Makespan value obtained according to the results of processing using Least Slack algorithm, SPT (Short Processing Time) and Johnson dalah as follows: Table 6. Makespan production process Algoritma Makespan Least Slack 11.68 days SPT 10.44 days Johnson 10.81 days

Seen from the table above scheduling using SPT produced the shortest makespan in the production process from A to E. 4.2.3. Slack minimization comparisons Slack values obtained according to the results of processing using Least Slack algorithm, SPT (Short Processing Time) and Johnson are as follows: Table 7 Start Slack Production Process
No. Task 1 2 3 4 5 Task Name Product A Product B Product C Product D Product E Total Slack Start Slack (hari) Least Slack 1.84 4.46 2.78 7.38 0 16.46 SPT 3.04 0.38 2.11 0 3.04 8.57 Johnson 3 3.53 0.24 0 1.16 7.93

The following chart Total Slack to algorithms used:

Figure 4. Total slack graph and algorithms In the graph in above ones discussed next Johnson give total slack which smallest on the manufacture of products A until E. 4.2.4. Comparison Between Criteria With AHP Criteria to be used in data analysis using AHP are as follows: 1. 2. 3. Engine efficiency Makespan minimization Slack minimization The following table is a comparison between krtiteria with AHP matrix : Table 8. Comparison between criteria Efisiensi Minimasi Efisiensi Mesin 1.00 0.33 Minimasi Makespan 3.00 1.00 Minimasi Slack 0.50 0.33 4.50 1.67

Minimasi 2.00 3.00 1.00 6.00

4.2.5. Comparison Between Alternative Under Each Criteria Alternative algorithm is the method that will be used : 1. Least Slack algorithm 2. SPT algorithm 3. Johnson algorithm Table 9 to Table 11 is a comparison table between alternatives for each criterion with AHP matrix :

Table 9. Comparison between alternative engines efficiency criteria

Efisiensi Mesin Least Slack SPT Johnson

Least Slack 1.00 0.50 0.33 1.83

SPT 2.00 1.00 0.50 3.50

Johnson 3.00 2.00 1.00 6.00

Table 10. Comparison between alternative criteria minimization of makespan

Minimasi Makespan Least Slack SPT Johnson

Least Slack 1.00 5.00 3.00 9.00

SPT 0.20 1.00 0.33 1.53

Johnson 0.33 3.00 1.00 4.33

Table 11. Comparison Between Slack Minimization Alternative Criteria

Minimasi Slack Least Slack Least Slack 1.00 SPT 2.00 Johnson 3.00 6.00

SPT 0.50 1.00 2.00 3.50

Johnson 0.33 0.50 1.00 1.83

After all the comparisons between alternatives each criterion has been charged and processed then obtained weight all local priotitas. The next step is to perform multiplication operation between the matrix containing the local priorities that will ultimately result in a global priority. 4.2.6. The results of each criterion priority The multiplication of matrix comparisons between criteria and comparison between alternative matrices are shown in Table 12. Table 12. Alternative priorities and priority algorithm selection criteria of issues
Criteria Weight Least Slack SPT Johnson Machine Efficiency 0.25 0.54 0.30 0.16 Minimization Minimization Makespan Slack 0.59 0.16 0.11 0.49 0.63 0.89 0.26 1.62 Criteria Priority 0.28 0.59 0.45

The numbers below the line indicate the local priorities of each matrix comparison between alternatives. If only the numbers below the line are considered the SPT algorithm only considered the best for a single criterion, namely makespan minimization, together with the algorithms are superior in slack least one criterion is efficiency machine. However, because the algorithm is superior to SPT on the criteria that are considered important, namely makespan minimization, the SPT algorithm is considered as the best scheduling

method to study the case in pharmaceutical industry. This situation is a little higher than Johnson's algorithm is superior to the criteria that are not so important that the priority weights only reaches 0:45. While the algorithm is Least Slack scored 0:28, because it excels in the most important criteria. V. Conclusion From the results of the work of sorting Least Slack algorithm approach, SPT and Johnson with the help of software Microsoft Project 2007, which gives the value of the highest engine efficiency and is Least Slack algorithm, gives the minimum makespan value is SPT, while Johnson algorithm gives the total slack lowest. After analyzing the decision-making, the AHP criteria most important objective is makespan minimization, and the most appropriate algorithm is used for the purpose of minimizing makespan criteria is SPT. Based on this study SPT algorithm can be used as a standard in making a scheduling method to obtain the optimal production process Microsoft Project 2007 can be applied in the company to make a machine in the company's scheduling system. With the scheduling system, the company will be more regular in the production process to the fullest VI. 1. 2. 3. 4. Reference Ginting, Rosnani. Penjadwalan Mesin. Graha Ilmu. Yogyakarta. 2009 Muir, C. Nancy. Microsoft Project 2007. Wiley Publishing. Canada.2007 Permadi S., Bambang. AHP. Jakarta. 1992 Pinedo, L. Michael. Scheduling, Theory, Algorithms, and Systems. New York University. 2008. 5. 6. Statistics Indonesia. Statistical Yearbook of Indonesia 2012. Jakarta. 2012 http://hdr.undp.org. accessed at: 25 February 2013