scholarly journals RANCANG BANGUN MODEL LEAN PRODUCTIVITY DENGAN PENDEKATAN OBJECTIVE MATRIX - VALUE STREAM MAPPING - ECRS (STUDI KASUS: PT. X)

2017 ◽  
Vol 5 (3) ◽  
Author(s):  
Muhammad Ichsan Fajrianto ◽  
Tiena Gustina Amran ◽  
Nora Azmi
Keyword(s):  
Cost Reduction ◽  
T Test ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Master Cylinder ◽  
Value Stream ◽  
Tier 1 ◽  
Combine Tool ◽  
Original Equipment Manufacturers

<p>Original Equipment Manufacturers (OEM) merupakan model bisnis untuk menggunakan<br />pihak ketiga sebagai subkontraktor atau pemasok bagian-bagian tertentu dalam rangka integrasi<br />produk akhir. Pemasok OEM platform dibagi beberapa tingkatan. Pemasok tingkatan 1 (tier 1) adalah<br />pemasok yang terbesar, tier 1 memproduksi barang yang penting untuk perusahaan OEM. Perusahaan<br />OEM 1st tier tidak terlepas dari waste yang ada di perusahaan itu sendiri. Studi kasus dilakukan pada<br />perusahaan manufaktur OEM supplier tier 1 yang memproduksi brake untuk kendaraan roda 2 (two<br />wheels). Besarnya kuantitas permintaan dari produsen sepeda motor (OEM) dan varian modelnya,<br />serta masih terdapat loss genba (waste) di shop-floor, dan adanya cost reduction yearly dari<br />perusahaan OEM. Maka, perlu dibuat sebuah model atau sistem untuk meningkatkan kinerja<br />perusahaan. Model yang dibuat berdasarkan prinsip lean yang bertujuan untuk mengurangi atau<br />menghilangkan waste pada proses manufaktur dengan tools Objective Matrix (OMAX), Value Stream<br />Mapping (VSM), Eliminate-Combine-Rearrange-Simplify (ECRS) dimana goal akhir adalah<br />peningkatan kinerja (produktivitas) perusahaan. Part yang dipilih untuk improvement adalah line<br />machining master cylinder 5P0, dengan nilai produktivitas dasar OMAX adalah 300. Dilakukan<br />analisa dengan VSM sebagai visualisasi waste yang terdapat pada shop-floor saat ini. Diperoleh waste<br />yakni motion, over process dan waiting. Setelah dilakukan analisis waste yang ada, berikutnya adalah<br />melakukan perbaikan menggunakan pendekatan ECRS. Perbaikan dilakukan menggunakan<br />pendekatan ECRS. Hasil yang diperoleh gap waktu standar sebelum dan sesudah adalah 8.29 detik<br />(atau turun sebesar 17%). Perbaikan yang dilakukan adalah eliminate proses facing machining,<br />combine tool burrytori, rearrange penempatan material, simplify penempatan air minum di line.<br />ECRS menunjukkan hasil menaikkan nilai produktivitas di bulan berikutnya sebesar 432, 959, 334,<br />770, 921, 959. Hasil lainnya adalah 4 bulan setelah aktivitas, line machining untuk kebutuhan master<br />cylinder 5P0 yang sebelumnya menggunakan 6 line direduksi menjadi 5 line (reduksi 1 line). Dari<br />hasil pengujian T-test terdapat perbedaan yang signifikan antara nilai produktivitas dasar terhadap<br />nilai produktivitas setelah perbaikan.</p>

Development of Computerize Value Stream System

2014 ◽  
Vol 915-916 ◽  
pp. 1405-1411
Author(s):  
A.N.A. Ahmad ◽  
Sulaiman Hj. Hasan ◽  
H. Norafifah
Keyword(s):  
Lean Manufacturing ◽  
Mapping Method ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Traditional Concept ◽  
Value Stream ◽  
Stream System ◽  
Manufacturing Company ◽  
Value Streams ◽  
Individual Value

Value stream mapping (VSM) was initially developed to use of the suite of tools to help researcher or practitioner to identify waste in individual value streams and find an appropriate method to its removal. The process itself is simple and straightforward is used to identify waste using lean manufacturing technique, determined causes of the waste through the value stream mapping method and to propose solution to improve workplace environment. In this project is made an attempt to computerize the process though the application of VSM. Computerize value stream system is basically a method which is an internet networking system combining traditional concept of value stream mapping method to be used at manufacturing company to reduce wastes. This paper summarizes the way to develop an internet, online and network based of an efficient computerize value stream system to improve operation value of the manufacturing company. This paper reviews the design of package that will replace the manual method of doing VSM. This package will be applied in a real shop floor environment.

Production Improvement in an Aircraft Manufacturing Company Using Value Stream Mapping Approach

2014 ◽  
Vol 660 ◽  
pp. 1038-1042 ◽  
Author(s):  
Md Saidin Wahab ◽  
Kamsidi Abd Malek Sidek ◽  
Mohd Shahir Yahya ◽  
Muhammad Mustaqim Ahmat
Keyword(s):  
Information Flow ◽  
Simulation Software ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Cycle Times ◽  
Value Stream ◽  
Aircraft Manufacturing ◽  
Current State ◽  
Manufacturing Company

The purpose of this study is to develop a value stream mapping for a production in an aircraft manufacturing company. The process begins with creating a current state map and understands the production flow and the current cycle times. This provides the information needed to produce a future state map. The goal is to identify and eliminate the waste, which is any activity that does not add value to the final product, in the production process. In order to collect the information needed, the study was conducted within the production facility to enable the researcher gained knowledge and familiarized with the production flow and the activities being performed at the shop floor. Parameters such as cycle times, down times, work in process (WIP) for inventory and material, and information flow paths were recorded. This information will enable the researcher to visualize the current state of the process activities by mapping the material and information flow and looking for opportunities to eliminate wastes. ARENA simulation software package was used to simulate and analyze the process flow and times. Result from the analysis shows that there are areas where the company can further improve their production system. The results show the improvement of the cycle time up to 22% based on the new proposed arrangement of the layout. Therefore the propose layout will be guided to the company in order to improve their production.

Energy Value Stream Mapping, Development and Application of a Tool to Reduce Energy Inefficiencies of the Production Processes

2015 ◽  
Author(s):  
Michele Germani ◽  
Daniele Del Duca ◽  
Andrea Luzi ◽  
Fabio Camorani
Keyword(s):  
Energy Consumption ◽  
Minimum Energy ◽  
Critical Issue ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Energy Value ◽  
Energy Management Systems ◽  
Value Stream ◽  
Minimum Energy Consumption ◽  
Production Processes

Over the last years, the industrial energy consumption has become a critical issue and several energy management systems have been developed. At the same time, the lean philosophy has been used to evaluate the critical points of the production processes. One of the main tools used by lean champions is the Value Stream Mapping (VSM) to identify “bottlenecks” and also to provide graphically areas of interest for improvement within the shop floor. Current VSM models do not include information about energy as a fundamental content. To overcome this lack, the present work is focused on the development of a new extended VSM tool able to map the energy consumption. Energy value Stream mapping (EVSM) is a tool to evaluate issues related to the energy consumption. Through it, the energy manager can pursue the minimum energy consumption. The proposed tool has been applied and tested in a real case study.

Investigating the effect of value stream mapping on operational losses: a case study

2018 ◽  
Vol 16 (3) ◽  
pp. 478-500 ◽  
Author(s):  
Ali-Asghar Dadashnejad ◽  
Changiz Valmohammadi
Keyword(s):  
Cost Reduction ◽  
Structural Equation ◽  
Partial Least Square ◽  
The Body ◽  
Least Square ◽  
Equation Modeling ◽  
Value Stream Mapping ◽  
Manufacturing Companies ◽  
Content Type ◽  
Value Stream

Purpose One of most important tools for lean production is value stream mapping (VSM), which identifies and reduces errors, losses, waiting time and improves value adding time, leading to enhanced product quality through empowering production unit in terms of production risk and cost reduction in the long term. This paper aims to present a general concept for production flow, such that value stream can be fully understood. For this purpose, this research investigates the effect of value stream on operational losses and analyzes the process that has been conducted in preview step operationally, using the discovered pattern. Design/methodology/approach In this research, related processes were evaluated after the review of the relevant literature and after extracting operational basics of lean approach using a questionnaire, such that all factors affecting operational losses and VSM were assessed. Then comparison between the result of current state map and the result of future state map were done and analyzed. Cronbach’s alpha was calculated to test the designed questionnaire’s reliability, which resulted in an acceptable level of 0.845. The structural equation modeling method through SPSS and Smart–Partial Least Square was applied to analyze the data and test the hypotheses. Findings The results reveal that implementing required changes and corrections will lead directly to production process improvement, which, in turn, results in higher customer satisfaction because of cost reduction and quality enhancement. Also, tests of the hypotheses confirm that VSM affects six operational losses, namely, equipment failures, set-up and changeovers, idling and minor stoppages, reduced speed operation, scrap and rework and startup losses. Research limitations/implications Though this study was done in a single manufacturing company, the implementation of this study delivers important results that can be deployed in other such manufacturing companies. Practical implications This tool helps to identify loss points, make right decisions, and choose the best methods and lean tools for improvement. The surveyed company can integrate lean principles and tools and achieve better results using this tool. Also, this tool could be used to analyze the process and to define necessary changes before changing the process components. Originality/value This study contributes to the body of knowledge in manufacturing research as the study regarding the effects of improvement opportunities identified through VSM on operational losses is still something new.

scholarly journals Using Dynamic Value Stream Mapping And Lean Accounting Box Scores To Support Lean Implementation

2010 ◽  
Vol 3 (8) ◽  
pp. 67-76 ◽  
Author(s):  
Stephen L. Woehrle ◽  
Louay Abou-Shady
Keyword(s):  
Lean Manufacturing ◽  
Competitive Market ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Effective Management ◽  
Rapid Reduction ◽  
Lean Implementation ◽  
Management Philosophy ◽  
Value Stream ◽  
Lean Accounting

Lean has proven to be an effective management philosophy for improving businesses in a competitive market by eliminating waste and improving operations.  An impact of implementing lean projects is the rapid reduction in inventory levels, which gives management the false impression that profits are decreasing while workers on the shop floor observe improvements in operations and increased floor space. This paper explores the literature on lean manufacturing, value stream mapping (VSM), Simulation and lean accounting in order to incorporate and integrate them for the purpose of solving the dilemma between lean implementation benefits and financial and accounting reporting methods.

Reduction of Cost Employing Lean Supply Chain in Rubber Glove Industry

2013 ◽  
Vol 844 ◽  
pp. 421-424
Author(s):  
Sukonthip Hongpiriyakul ◽  
Nikorn Sirivongpaisal ◽  
Sakesun Suthummanon ◽  
Wanatchapong Kongkaew ◽  
Pallapat Penchamrat
Keyword(s):  
Supply Chain ◽  
Energy Cost ◽  
Cost Reduction ◽  
Lead Time ◽  
Labor Cost ◽  
Value Stream Mapping ◽  
Rubber Glove ◽  
Value Stream ◽  
Time Value ◽  
Lean Supply Chain

Rubber glove industry in the supply chain has become increasingly important because of the significant change in consumer behaviors, which turn to focus on healthcare and disease protection. Thailand is among the leading exporting countries of rubber glove. Under current situation, with high labor cost and energy cost having an impact on production cost, the need for cost reduction in the industry is extremely of concern. This research demonstrates application of the lean supply chain for cost reduction in the industry. The aim is to lower the total supply chain cost by reducing the lead time. Value stream mapping is employed to analyze non valued activities (wastes) in the supply chain. Propositions for eliminating the wastes are presented.

Implementing Lean Techniques on the Shop Floor Improvement of a Delivery Company

2014 ◽  
Vol 989-994 ◽  
pp. 2811-2814
Author(s):  
Jason Shay ◽  
Peter Iming Shieh
Keyword(s):  
Material Handling ◽  
Manufacturing Industries ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Lean Management ◽  
Value Stream ◽  
Operation Costs ◽  
Business Efficiency ◽  
Domestic Company ◽  
Future Condition

CTC Express is the leading domestic company in delivery service and wants to improve their business efficiency by establishing lean management in the shop floor activities. Lean management is generally adopted by the manufacturing industries as a significant technique to reduce waste and operation costs. This paper investigates the continuous improvement through value stream mapping, begins with describing the current situation and proposes the future condition. Several improvements were implemented in the company such as the transformation of automation process, better result in visual control and standardization processes. The new proposed system has shown being able to reduce the works of loading/unloading and in the same time to increase the performance of material handling in each cycle time.

Sign in / Sign up

Export Citation Format

Share Document