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All Journal Implementasi Manajemen & Kewirausahaan
Cucu Wahyudin
Department of Industrial Engineering, Faculty of Manufacturing Technology, Universitas Jenderal Achmad Yani
Decision Sciences, Operations Research & Management Economics, Econometrics & Finance

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Integration of Ranked Positional Weight (RPW) and Theory Of Constraints (TOC)–Drum Buffer Rope (DBR) for improving the efficiency of sub-assembly engine and transmission lines Cucu Wahyudin; Sinta Rahmawati; Rinto Yusriski
Implementasi Manajemen & Kewirausahaan Vol 6 No 1 (2026): IMKA JOURNAL
Publisher : Prodi Manajemen Fakultas Ekonomi dan Bisnis Universitas Wijaya Putra

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.38156/imka.v6i1.841

Abstract

Assembly line imbalance is a significant issue in the manufacturing of complex products, often resulting in bottlenecks, idle time, and efficiency losses. This study integrates the Ranked Positional Weight (RPW) method with the Theory of Constraints (TOC) using the Drum–Buffer–Rope (DBR) mechanism to improve the performance of the sub-assembly line for an APC 6×6 engine and transmission. The analysis involved 39 work elements across eight stations, processed through standard time measurement, cycle-time calculation, and workstation formation using RPW. The balancing results show a reduction in stations from eight to four, leading to a twofold improvement in line efficiency—from 37.47% to 74.94%—along with a decrease in balance delay from 62.53% to 25.06% and a smoother workload distribution (smoothness index reduced from 695.66 to 486.58). The integration of TOC–DBR ensured a controlled production rhythm based on the capacity of the Critical Constraint Resource (CCR), with a 25% protective buffer to maintain flow continuity. Backward scheduling determined job release timing, aligning throughput with actual capacity. These findings confirm that combining RPW and TOC–DBR effectively enhances both assembly-line efficiency and the realism of production scheduling.
Co-Authors Rinto Yusriski Sinta Rahmawati