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BAB IV

PENGUMPULAN DAN PENGOLAHAN DATA

4.1 PENGUMPULAN DATA

4.1.1 Pengumpulan Data Rencana Produksi Agregat

Pengumpulan data Rencana Produksi Agregat ini terdiri dari komponen-


komponen data awal, data hari kerja dan demand. Komponen data awal terdiri
dari jumlah inventori awal, jam kerja, waktu baku, berbagai macam cost, juga
komponen lainnya. Data hari kerja terdiri dari 12 periode dengan demand yang
diambil dari hasil pengolahan data pada modul 1 Forecasting pada Metode
Regresi Linier karena pada metode tersebut nilai errornya paling rendah.

Tabel 4.1 Komponen Data Awal Tabel 4.2 Data Hari Kerja Awal dan
Demand
Inv.Awal 250 unit Periode Hari Kerja Demand
Jam Kerja 8 jam 1 21 10068
Max.OT 25% RT unit 2 19 10112
Max.SK 50% RT unit 3 21 10156
WB 1,67 jam/unit 4 20 10200
5 22 10244
Tk.Awal 12 Org
6 20 10288
Tk.Max 30 Org
7 21 10332
RT Cost 50000 /unit 8 19 10376
OT Cost 75000 /unit 9 20 10464
SK Cost 120000 /unit 10 21 10464
HR Cost 1000000 /org 11 20 10508
LO Cost 1500000 /org 12 19 10552
Inv.Cost 2500 /unit Total 243 123764
(Sumber: Pengumpulan Data) (Sumber: Pengumpulan Data)
4.2 PENGOLAHAN DATA

Pengolahan data Rencana Produksi Agregat ini terdiri dari tiga strategi. Pertama
strategi tenaga kerja tetap, kedua strategi tenaga kerja berubahdan yang ketiga
adalah strategi transportasi. Ketiga strategi tersebut digunakan untuk mencari
ongkos total.

4.2.1 Strategi Tenaga Kerja Tetap

Tabel 4.3 Strategi Tenaga Kerja Tetap (Round Up)


Periode HK Demand TK RMH UPRT UPOT Hiring Inventori Biaya RT Biaya Inventori Biaya OT Biaya Hiring Total Biaya
0 12 250
1 21 10068 17976 10764 -946 95 946 Rp 538,200,000 Rp 2,365,000 Rp - Rp 95,000,000 Rp 635,565,000
2 19 10112 16264 9738 -572 572 Rp 486,900,000 Rp 1,430,000 Rp - Rp - Rp 488,330,000
3 21 10156 17976 10764 -1180 1180 Rp 538,200,000 Rp 2,950,000 Rp - Rp - Rp 541,150,000
4 20 10200 17120 10251 -1231 1231 Rp 512,550,000 Rp 3,077,500 Rp - Rp - Rp 515,627,500
5 22 10244 18832 11276 -2263 2263 Rp 563,800,000 Rp 5,657,500 Rp - Rp - Rp 569,457,500
6 20 10288 17120 10251 -2226 2226 Rp 512,550,000 Rp 5,565,000 Rp - Rp - Rp 518,115,000
107
7 21 10332 17976 10764 -2658 2658 Rp 538,200,000 Rp 6,645,000 Rp - Rp - Rp 544,845,000
8 19 10376 16264 9738 -2020 2020 Rp 486,900,000 Rp 5,050,000 Rp - Rp - Rp 491,950,000
9 20 10464 17120 10251 -1807 1807 Rp 512,550,000 Rp 4,517,500 Rp - Rp - Rp 517,067,500
10 21 10464 17976 10764 -2107 2107 Rp 538,200,000 Rp 5,267,500 Rp - Rp - Rp 543,467,500
11 20 10508 17120 10251 -1850 1850 Rp 512,550,000 Rp 4,625,000 Rp - Rp - Rp 517,175,000
12 19 10552 16264 9738 -1036 1036 Rp 486,900,000 Rp 2,590,000 Rp - Rp - Rp 489,490,000
Total 243 123764 119 208008 124550 0 95 19896 Rp 6,227,500,000 Rp 49,740,000 Rp - Rp 95,000,000 Rp 6,372,240,000

(Sumber: Pengolahan Data)

Perhitungan:
a. Tenaga Kerja d. Unit Production Over Time

TK =
(∑ 𝐷𝑡 −𝐼𝑡−1 )
× WB UPOT =Demand – (UPRT + It – 1)
(∑ 𝐻𝐾×𝐽𝐾)
123764−250
UPOT1 = 10068 – (10764 + 250)
TK = × 1,67
243−8 = -946 unit
= 107 pekerja (Round Up) (maka disimpan di inventori, dan
nilai UPOT = 0)
b. Reguler Man Hour
RMH = HK × JK × TK e. Hiring
RMH1 = 21×8×107 Hiring = TK - TKawal
= 17976 jam = 107 - 12
= 95 pekerja
c. Unit Production Reguler Time
𝑅𝑀𝐻
UPRT = 𝑊𝐵
17976
UPRT1 = 1,67

= 10764 unit (Round Down)


f. Inventori
I1 = (UPRT+UPOT+It-1) - Dt i. BiayaUnit Production Over Time
= (10764+0+250)-10068 BOT = UPOT × Cost OT
= 946 unit BOT1 = 0×75000
= -
g. Biaya Unit Production Reguler
Time j. Biaya Hiring
BRT = UPRT × Cost RT BH = Hiring × Cost Hiring
BRT1 = 10764×50000 = 95×1000000
= Rp 538.200.000 = Rp 95.000.000

h. Biaya Inventori k. Biaya Total


BIn = Inventory × Cost Inventory BT = ∑ 𝐵𝑅𝑇 + ∑ 𝐵𝐼 + ∑ 𝑂𝑇 + ∑ 𝐵𝐻
BI1 = 946×2500 BT1 = Rp 538.200.000 + Rp
=Rp 2.365.000 2.365.000 + Rp0 + Rp 95.000.000
= Rp 635.565.000

Tabel 4.4 Strategi Tenaga Kerja Tetap (Round down)


Periode HK Demand TK RMH UPRT UPOT Hiring Inventori Biaya RT Biaya Inventori Biaya OT Biaya Hiring Total Biaya
0 12 250
1 21 10068 17808 10663 -845 94 845 Rp 533,150,000 Rp 2,112,500 Rp - Rp 94,000,000 Rp 629,262,500
2 19 10112 16112 9647 -380 380 Rp 482,350,000 Rp 950,000 Rp - Rp - Rp 483,300,000
3 21 10156 17808 10663 -887 887 Rp 533,150,000 Rp 2,217,500 Rp - Rp - Rp 535,367,500
4 20 10200 16960 10155 -842 842 Rp 507,750,000 Rp 2,105,000 Rp - Rp - Rp 509,855,000
5 22 10244 18656 11171 -1769 1769 Rp 558,550,000 Rp 4,422,500 Rp - Rp - Rp 562,972,500
6 20 10288 16960 10155 -1636 1636 Rp 507,750,000 Rp 4,090,000 Rp - Rp - Rp 511,840,000
106
7 21 10332 17808 10663 -1967 1967 Rp 533,150,000 Rp 4,917,500 Rp - Rp - Rp 538,067,500
8 19 10376 16112 9647 -1238 1238 Rp 482,350,000 Rp 3,095,000 Rp - Rp - Rp 485,445,000
9 20 10464 16960 10155 -929 929 Rp 507,750,000 Rp 2,322,500 Rp - Rp - Rp 510,072,500
10 21 10464 17808 10663 -1128 1128 Rp 533,150,000 Rp 2,820,000 Rp - Rp - Rp 535,970,000
11 20 10508 16960 10155 -775 775 Rp 507,750,000 Rp 1,937,500 Rp - Rp - Rp 509,687,500
12 19 10552 16112 9647 130 0 Rp 482,350,000 Rp - Rp 9,750,000 Rp - Rp 492,100,000
Total 243 123764 106 206064 123384 130 94 12396 Rp 6,169,200,000 Rp 30,990,000 Rp 9,750,000 Rp 94,000,000 Rp 6,303,940,000

(Sumber: Pengolahan Data)

Perhitungan:
a. TK1 = 106 (Round Down)
b. RMH1 = 17808
c. UPRT1 = 10663 (Round Down)
d. UPOT1 =0
e. Hiring = 94
f. Inventori1 = 845
g. Biaya Unit Production Reguler Time
BRT1 = Rp533.150.000
h. Biaya Inventori
BI1 = Rp 2.112.500
i. Biaya Unit Production Over Time
BOT 1 =-
j. Biaya Hiring
BH1 = Rp 94.000.000
k. Biaya Total1 = Rp 629.262.500

4.2.2 Strategi Tenaga Kerja Berubah

Tabel 4.5 Strategi Tenaga Kerja Berubah (Round Up)


Periode HK Demand Tk.Dihitung Tk.Terpakai RMH UPRT UPOT SK Hiring Lay Off Inventori Biaya RT Biaya Inv Biaya OT Biaya Hiring Biaya Lay off Total Biaya
0 12 12 250
1 21 10068 97.60 98 16464 9858 210 86 0 Rp 492,900,000 Rp - Rp 15,750,000 Rp 86,000,000 Rp - Rp 594,650,000
2 19 10112 108.35 109 16568 9920 192 11 0 Rp 496,000,000 Rp - Rp 14,400,000 Rp 11,000,000 Rp - Rp 521,400,000
3 21 10156 98.47 99 16632 9959 197 10 0 Rp 497,950,000 Rp - Rp 14,775,000 Rp - Rp 15,000,000 Rp 527,725,000
4 20 10200 103.85 104 16640 9964 236 5 0 Rp 498,200,000 Rp - Rp 17,700,000 Rp 5,000,000 Rp - Rp 520,900,000
5 22 10244 94.83 95 16720 10011 233 9 0 Rp 500,550,000 Rp - Rp 17,475,000 Rp - Rp 13,500,000 Rp 531,525,000
6 20 10288 104.77 105 16800 10059 229 10 0 Rp 502,950,000 Rp - Rp 17,175,000 Rp 10,000,000 Rp - Rp 530,125,000
7 21 10332 100.22 101 16968 10160 172 4 0 Rp 508,000,000 Rp - Rp 12,900,000 Rp - Rp 6,000,000 Rp 526,900,000
8 19 10376 111.25 112 17024 10194 182 11 0 Rp 509,700,000 Rp - Rp 13,650,000 Rp 11,000,000 Rp - Rp 534,350,000
9 20 10464 106.61 107 17120 10251 213 5 0 Rp 512,550,000 Rp - Rp 15,975,000 Rp - Rp 7,500,000 Rp 536,025,000
10 21 10464 101.53 102 17136 10261 203 5 0 Rp 513,050,000 Rp - Rp 15,225,000 Rp - Rp 7,500,000 Rp 535,775,000
11 20 10508 107.07 108 17280 10347 161 6 0 Rp 517,350,000 Rp - Rp 12,075,000 Rp 6,000,000 Rp - Rp 535,425,000
12 19 10552 113.19 114 17328 10376 176 6 0 Rp 518,800,000 Rp - Rp 13,200,000 Rp 6,000,000 Rp - Rp 538,000,000
Total 243 123764 1247.74 1254 202680 121360 2404 0 135 33 0 Rp 6,068,000,000 Rp - Rp 180,300,000 Rp 135,000,000 Rp 49,500,000 Rp 6,432,800,000

(Sumber: Pengolahan Data)

Perhitungan:
a. Tenaga Kerja b. Reguler Man Hour
(𝐷𝑡 −𝐼𝑡−1 ) RMH = HK × JK × TK
TK = × WB
(𝐻𝐾×𝐽𝐾)
(10068−250)
RMH1 = 21 × 8 × 98
TK1 = × 1,67
(21×8) = 16464
= 97,60
= 98 pekerja (Round Up) c. Unit Production Reguler Time
𝑅𝑀𝐻
UPRT = 𝑊𝐵
16464
UPRT1 = 1,67

= 9858 unit (Round Down)


d. Unit Production Over Time i. Biaya Inventori
UPOT =Demand – UPRT BIn = Inventory × Cost Inventory
UPOT1 = 10068 – 9858 = 0 × 2500
=210 unit = -

e. Hiring j. Biaya Unit Production Over Time


Hiring =TK - TKawal BOT = UPOT × Cost OT
Hiring1= 98 - 12 BOT1 = 210 × 75000
=86 pekerja = Rp15.750.000

f. Lay Off k. Biaya Hiring


LayOff =TKawal – TK BH = Hiring × Cost Hiring
LayOff3= 109 - 99 BH1 =86 × 1000000
= 10 = Rp86.000.000

g. Inventori l. Biaya Lay Off


I =0 BL = Lay Off ×Cost Lay Off
(Hasil UPOT positif maka nila BL3 = 10× 1.500.000
inventori 0) = Rp15.000.000

h. Biaya Unit Production Reguler m. Biaya Total


Time BT =
BRT = UPRT × Cost RT ∑ 𝐵𝑅𝑇 + ∑ 𝐵𝐼 + ∑ 𝑂𝑇 + ∑ 𝐵𝐻 +
BRT1 = 9858 x 5000 ∑ 𝐵𝐿
= Rp 492.900.000 BT1 = Rp 492.900 + Rp 0 + Rp
15.750.000 + Rp 86.000.000 + Rp 0
= Rp594.650.000
Tabel 4.6 Strategi Tenaga Kerja Berubah (Round Down)
Periode HK Demand Tk.Dihitung Tk.Terpakai RMH UPRT UPOT SK Hiring Lay Off Inventori Biaya RT Biaya Inv Biaya OT Biaya Hiring Biaya Lay off Total Biaya
0 12 12 250
1 21 10068 97.60 97 16296 9758 60 85 0 Rp 487,900,000 Rp - Rp 4,500,000 Rp 85,000,000 Rp - Rp 577,400,000
2 19 10112 108.35 108 16416 9829 275 11 10 0 Rp 491,450,000 Rp - Rp 20,625,000 Rp 11,000,000 Rp 15,000,000 Rp 538,075,000
3 21 10156 98.47 98 16464 9858 298 0 Rp 492,900,000 Rp - Rp 22,350,000 Rp - Rp - Rp 515,250,000
4 20 10200 103.85 103 16480 9868 332 5 9 0 Rp 493,400,000 Rp - Rp 24,900,000 Rp 5,000,000 Rp 13,500,000 Rp 536,800,000
5 22 10244 94.83 94 16544 9906 336 0 Rp 495,300,000 Rp - Rp 25,200,000 Rp - Rp - Rp 520,500,000
6 20 10288 104.77 104 16640 9964 312 10 4 0 Rp 498,200,000 Rp - Rp 23,400,000 Rp 10,000,000 Rp 6,000,000 Rp 537,600,000
7 21 10332 100.22 100 16800 10059 243 0 Rp 502,950,000 Rp - Rp 18,225,000 Rp - Rp - Rp 521,175,000
8 19 10376 111.25 111 16872 10102 -49726 11 5 49726 Rp 505,100,000 Rp 124,315,000 Rp - Rp 11,000,000 Rp 7,500,000 Rp 647,915,000
9 20 10464 106.61 106 16960 10155 -74691 5 74691 Rp 507,750,000 Rp 186,727,500 Rp - Rp - Rp 7,500,000 Rp 701,977,500
10 21 10464 101.53 101 16968 10160 -119696 119696 Rp 508,000,000 Rp 299,240,000 Rp - Rp - Rp - Rp 807,240,000
11 20 10508 107.07 107 17120 10251 -999743 6 999743 Rp 512,550,000 Rp 2,499,357,500 Rp - Rp 6,000,000 Rp - Rp 3,017,907,500
12 19 10552 113.19 113 17176 10285 -1499733 6 1499733 Rp 514,250,000 Rp 3,749,332,500 Rp - Rp 6,000,000 Rp - Rp 4,269,582,500
Total 243 123764 1247.74 1242 200736 120195 0 134 33 2743589 Rp 6,009,750,000 Rp 6,858,972,500 Rp 139,200,000 Rp 134,000,000 Rp 49,500,000 Rp 13,191,422,500

(Sumber: Pengolahan Data)

Perhitungan:
a. TK = 97,60 = 97 pekerja (Round Down)
b. RMH1 = 16296 jam
c. UPRT1 = 9758 unit
d. UPOT1 = 60
e. Hiring1 = 85
f. Lay Off1 =0
g. Inventori1 = 0
h. Biaya Unit Production Reguler Time
BRT 1 = Rp 487.900.000
i. Biaya Inventori
BI1 =-
j. Biaya Unit Production Over Time
BOT 1 = Rp 4.500.000
k. Biaya Hiring
BH1 = Rp 85.000.000
l. Biaya Lay Off
BL1 = -
m. Biaya Total1 = Rp 577.400.000
Tabel 4.7 Strategi transportasi
Kapasitas Tak
Periode 1 2 3 4 5 6 7 8 9 10 11 12 Kapasitas Cost
Terpakai
50000 52500 55000 57500 60000 62500 65000 67500 70000 72500 75000 77500
RT 10764 510
9849 405
75000 77500 80000 82500 85000 87500 90000 92500 95000 97500 100000 102500
1 OT 2691 2691 Rp 513.712.500

120000 122500 125000 127500 130000 132500 135000 137500 140000 142500 145000 147500
SK 5382 5382

50000 52500 55000 57500 60000 62500 65000 67500 70000 72500 75000
RT 9738 0
9738
75000 77500 80000 82500 85000 87500 90000 92500 95000 97500 100000
2 OT 2435 2435 Rp 486.900.000
120000 122500 125000 127500 130000 132500 135000 137500 140000 142500 145000
SK 4869 4869

50000 52500 55000 57500 60000 62500 65000 67500 70000 72500
RT 10764 577
10187
75000 77500 80000 82500 85000 87500 90000 92500 95000 97500
3 OT 2691 2691 Rp 509.350.000

120000 122500 125000 127500 130000 132500 135000 137500 140000 142500
SK 5382 5382
50000 52500 55000 57500 60000 62500 65000 67500 70000
RT 10251 20
10231
75000 77500 80000 82500 85000 87500 90000 92500 95000
4 OT 2563 2563 Rp 511.550.000

120000 122500 125000 127500 130000 132500 135000 137500 140000


SK 5126 5126

50000 52500 55000 57500 60000 62500 65000 67500


RT 11276 933
10275 68
75000 77500 80000 82500 85000 87500 90000 92500
5 OT 2819 2819 Rp 517.320.000
120000 122500 125000 127500 130000 132500 135000 137500
SK 5638 5638
50000 52500 55000 57500 60000 62500 65000
RT 10251 0
10251
75000 77500 80000 82500 85000 87500 90000
6 OT 2563 2563 Rp 512.550.000

120000 122500 125000 127500 130000 132500 135000


SK 5126 5126

50000 52500 55000 57500 60000 62500


RT 10764 0
10363 401
75000 77500 80000 82500 85000 87500
7 OT 2691 2691 Rp 539.202.500
120000 122500 125000 127500 130000 132500
SK 5382 5382

50000 52500 55000 57500 60000


RT 9738 0
9738
75000 77500 80000 82500 85000
8 OT 2435 1967 Rp 522.500.000
268 200
120000 122500 125000 127500 130000
SK 4869 4869

50000 52500 55000 57500


RT 10251 0
10251
75000 77500 80000 82500
9 OT 2563 2563 Rp 512.550.000
120000 122500 125000 127500
SK 5126 5126

50000 52500 55000


RT 10764 0
10495 269
75000 77500 80000
10 OT 2691 2691 Rp 538.872.500

120000 122500 125000


SK 5382 5382
50000 52500
RT 10251 0
10251
75000 77500
11 OT 2563 1699 Rp 579.462.500
19 845
120000 122500
SK 5126 5126

50000
RT 9738 0
9738
75000
12 OT 2435 2435 Rp 486.900.000
120000
SK 4869 4869
Demand 10099 10143 10187 10231 10275 10319 10363 10407 10451 10495 10539 10583 Rp 6.230.870.000

(Sumber: Pengolahan Data)