Demand-Driven Takt-Time Synchronization for Stabilizing Mixed-Model Output Across Fluctuating Consumer-Goods Manufacturing Production Lines

Johni S Pasaribu (Politeknik Piksi Ganesha)
Mohammad H. Holle (Universitas Islam Negeri Abdul Muthalib Sangadji Ambon)
Sitti Rachmawati Yahya (Universitas Siber Asia)
Reni Koibur (Universitas Ottow Geissler Papua)

Journal of Industrial Engineering and Management
Vol 2, No 1 (2024)

Consumer goods manufacturers must adapt production rhythm to demand that shifts daily between normal, high-season, and promotional-surge patterns while operating mixed-model lines with frequent changeovers. This study examines 88 sequential production days of demand and takt-time records, 60 changeover events across three product variants, and 12 months of synchronization key-performance indicators from a fast-moving consumer-goods plant. The objective is to describe the operational profile of a demand-driven takt-time synchronization practice relative to a conventional push approach. Mean daily demand ranges from 2,675 to 4,091 units, producing calculated takt times between 6.13 and 10.30 seconds. Of 60 recorded changeover events against a 15-minute SMED target, only five meet the target. In the demand-driven period, mean schedule adherence rises from 79.5% to 96.5%, overtime drops from 26.1 to 7.0 hours per month, and output variance decreases from 16.9% to 3.3% compared with the conventional-push period. Because the two periods cover different calendar months without a controlled experiment, the results are reported as descriptive associations rather than causal effects. The contribution is a transparent reporting structure that links demand variability, takt-time response, changeover constraint, and synchronization indicators for production-planning review