Development Of A Supply Chain Control Tower Based On Mass-customisation Concept In Make To Order Company (Case Study: Doilies Paper)

Abstract

In today’s competitive global market, manufacturing companies face the challenge of balancing mass customization with operational efficiency and fast response times. PT. Maesindo Indonesia, a manufacturer of doilies paper, operates under a make-to-order (MTO) system that often results in extended lead times, reducing customer satisfaction and overall performance. This research aims to reduce lead time and improve responsiveness by integrating the Customer Order Decoupling Point (CODP) strategy with a Supply Chain Control Tower (SCCT) framework, supported by Business Intelligence (BI) tools, using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. In the Define phase, the long lead time problem was identified; in Measure, baseline lead time was evaluated, showing averages of 1.436 days (oval), 1.428 days (rectangular), and 1.453 days (round); in Analyze, sales and production data were processed using Excel BI tools (Power Query and Power Pivot) through the ETL process to identify bottlenecks; in Improve, forecasting was applied to anticipate demand and prepare semi-finished goods at the slitting process as CODP, reducing manufacturing lead time; and in Control, an SCCT dashboard was developed to monitor lead time and KPIs in real time. The results demonstrate that integrating CODP and SCCT within the DMAIC framework, supported by BI tools, can effectively reduce lead time, enhance production efficiency, and improve customer satisfaction.