Peningkatan Produktivitas Leaf Spring Jenis Minicup Tipe MMS 2230 dengan Mengurangi Pemborosan Proses Produksi Melalui Penerapan Metode Lean Manufacturing

PT. Indospring is a manufacturing company that produces various springs for an automotive. Among those various springs, MSM 2230 type is the most produced spring at the company. The big problem in producing the spring was related with the high waste that had impact on the low productivity. The purpose of study was to analyze the waste by using the concept of lean manufacturing particularly to identify and eliminate nonvalue added activities. The study found that there were various wastes which waiting and excessive transportation were two dominant wastes with the contribution to total of wastes at 28.96% and 18.52% respectively. The appropriate tool for further analysis on wastes was selected by using value stream mapping analysis (VALSAT), and process activity mapping (PAM) was the best tool for analyzing wastes more profoundly. The use of PAM and other tools of fishbone diagram and failure mode effect analysis (FMEA) provided important information for improvement. The implementation of improvement displayed potential increase of productivity level by reducing the processing time of the spring from 113,926.83 minutes to 75,960 minutes

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Lean Manufacturing Applications in the Manufacturing Industry

MATEC Web of Conferences ◽

10.1051/matecconf/201822002005 ◽

2018 ◽

Vol 220 ◽

pp. 02005

Author(s):

Abdillah Arif Nasution ◽

Ikhsan Siregar ◽

Anizar ◽

Tigor Hamonangan Nasution ◽

Khalida Syahputri ◽

...

Keyword(s):

Lean Manufacturing ◽

Manufacturing Industry ◽

Value Added ◽

Added Value ◽

Value Stream Mapping ◽

Value Stream ◽

Mapping Analysis ◽

Manufacturing Applications ◽

Study Application

This research was conducted in manufacturing industry, so this research is based on case study application. This research serves to reduce waste in the industry when making a product. This study categorizes value-added work and which work has no added value. And it is measurable and has value, so it can be evaluated in the future. Later this will be poured or depicted on a map called Value stream mapping. This is a tool from Lean Manufacturing. Lean manufacturing is useful for analysing and reducing non value-added activities, value stream mapping analysis tools, 5L1H process mapping activities, and 5 why tools. From the results of this study obtained the efficiency of the process cycle and total estimation of the improvement of the lead time. This calculation can be an evaluation material for the company.

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APLIKASI LEAN SIX-SIGMA UNTUK MENGURANGI PEMBOROSAN DI BAGIAN PACKAGING SEMEN

JISI: Jurnal Integrasi Sistem Industri ◽

10.24853/jisi.7.2.143-153 ◽

2020 ◽

Vol 7 (2) ◽

pp. 143

Author(s):

Reni Dwi Astuti ◽

Lathifurahman Lathifurahman

Keyword(s):

Failure Mode ◽

Six Sigma ◽

Lean Manufacturing ◽

Fish Bone ◽

Lean Six Sigma ◽

Value Stream Mapping ◽

Effect Analysis ◽

Value Stream ◽

Transportation Motion

Hasil observasi di PT. Holcim Indonesia Tbk, pabrik Cilacap, didapati banyaknya pemborosan di bagian pengepakan semen, termasuk banyaknya produk cacat kemasan, sehingga banyak semen tercecer dan harus mengulangi proses pengepakan. Penelitian ini dilakukan untuk mengidentifikasi pemborosan selama proses pengepakan menggunakan pendekatan lean manufacturing dengan value stream mapping. Sementara tingkat kualitas dianalisis dengan metode six-sigma. Penyebab kecacatan produk dianalisis dengan fish-bone diagram. Failure Mode and Effect Analysis (FMEA) digunakan untuk merancang ususlan perbaikan. Pemborosan yang teridentifikasi meliputi : transportation, motion, waiting, over processing, dan defect. Usulan perbaikan untuk mengurangi pemborosan yaitu dengan penggabungan stasiun penimbangan dan stasiun pemeriksaan, sehingga memberikan estimasi peningkatan process cycle effisiensi dari 39,1% menjadi 46,69. Sedangkan upaya untuk mengurangi cacat produk dilakukan dengan perawatan preventif mesin packer.

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ANALISIS PENERAPAN KONSEP LEAN MANUFACTURING PADA PROSES PRODUKSI STAINLESS STEEL COIL UNTUK MEREDUKSI PEMBOROSAN (WASTE) DI PT. XYZ

JUMINTEN ◽

10.33005/juminten.v2i2.235 ◽

2021 ◽

Vol 2 (2) ◽

pp. 120-131

Author(s):

Ivonne Rakha Salsabila ◽

Rr. Rochmoeljati

Keyword(s):

Stainless Steel ◽

Failure Mode ◽

Lean Manufacturing ◽

Rolling Mill ◽

Value Stream Mapping ◽

Effect Analysis ◽

Steel Coil ◽

Value Stream ◽

Set Up ◽

Stainless Steel Coil

PT. XYZ merupakan perusahaan manufaktur yang bergerak dalam bidang produksi Stainless Steel Coil. PT. XYZ berharap dapat mengurangi pemborosan dalam proses produksinya, sehingga perusahaan dapat mendapatkan laba yang lebih besar dan mampu bersaing di industri saat ini. Tujuan dari penelitian yang dilakukan adalah untuk mengidentifikasi, mereduksi dan memberikan usulan perbaikan terhadap pemborosan (waste) pada proses produksi Stainless Steel Coil. Metode yang digunakan adalah konseplean manufacturing dengan tools value stream mapping dan bantuan metode Failure Mode and Effect Analysis (FMEA). Berdasarkan hasil penelitian pada value stream mapping didapatkan reduksi waktu dari 461 menit atau 27.660 detik menjadi 416 menit atau 24.960 detik. Berdasarkan Failure Mode and Effect Analysis (FMEA) diketahui akar penyebab masalah pada pemborosan (waste) tertinggi adalah Set up hot bucket yang kurang sesuai dan terjadi unplanned downtime atau kurang perawatan mesin. Rekomendasi perbaikan yang dapat diusulkan yaitu pembuatan jadwal pengurasan atau pembersihan hot bucket serta pengetatan terhadap set-up waktu hot bucket dan memperketat jadwal perawatan atau maintainance pada mesin Rolling Mill.

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Penerapan Lean Manufacturing Untuk Meminimasi Waste Waiting Pada Proses Produksi Hanger Sample Di CV. ABC Offset

Jurnal Rekayasa Sistem & Industri (JRSI) ◽

10.25124/jrsi.v4i01.212 ◽

2017 ◽

Vol 4 (01) ◽

pp. 76

Author(s):

Ireyna Nissa Octaviany ◽

Agus Alex Yanuar ◽

Meldi Rendra

Keyword(s):

Lean Manufacturing ◽

Value Stream Mapping ◽

Value Stream ◽

Current State ◽

Future State ◽

Make To Order ◽

Fishbone Diagram

ABC Offset adalah sebuah perusahaan yang bergerak dibidang percetakan dengan sistem make to order, dimana salah satu produk yang konsisten dipesan adalah hanger sample yang dipesan oleh perusahaan tekstil. Pada bulan Januari, Februari, Juni, Agustus, dan Oktober produksi tidak mencapai jumlah permintaan (73%, 80%, 92%, 71%, dan 50%). Hal tersebut disebabkan oleh permasalahan yang menghambat jalannya proses produksi. Melalui hasil observasi lapangan dan hasil pengolahan kuesioner, diketahui bahwa waste dominan yang terjadi pada proses pembuatan hanger sample adalah waste waiting dan waste inventory, dimana penelitian ini akan berfokus pada waste waiting. Upaya meminimasi waste waiting pada penelitian ini dilakukan dengan menggunakan pendekatan lean manufacturing. Penelitian diawali dengan melakukan pengumpulan data, seperti alur proses produksi, waktu siklus, kuesioner, data permintaan, data produksi, data jumlah operator, dan data jam kerja. Selanjutnya dilakukan pemetaan aliran proses eksisting dengan menggunakan value stream mapping (VSM) dan process activity mapping (PAM) current state. Tahap berikutnya adalah mengidentifikasi akar penyebab waste waiting dengan menggunakan diagram fishbone, diagram pareto, dan 5 whys. Setelah diketahui akar penyebabnya, dibuat usulan perbaikan guna meminimasi waste waiting dimana bidang ilmu yang akan digunakan adalah perancangan tata letak fasilitas dan perancangan produk. Kemudian value stream mapping (VSM) future state dibuat untuk memetakan perbaikan yang akan diusulkan..

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PERBAIKAN KUALITAS PROSES PRODUKSI DENGAN PENDEKATAN LEAN-SIGMA DI PT. AUTOKORINDO PRATAMA, GRESIK

Jurnal IPTEK ◽

10.31284/j.iptek.2016.v20i2.21 ◽

2016 ◽

Vol 20 (2) ◽

pp. 1

Author(s):

Ni Luh Putu Hariastuti ◽

Rony Nur Cahya

Keyword(s):

Failure Mode ◽

Six Sigma ◽

Value Stream Mapping ◽

Effect Analysis ◽

Pareto Chart ◽

Value Stream ◽

Fishbone Diagram

PT. Autokorindo Pratama Gresik adalah sebagai salah satu produsen velg truck dan bus di Indonesia. Penelitian ini menitiberatkan pada penggabungan konsep lean manufactur dan konsep six sigma yaitu lean sigma untuk memperbaiki kualitas. Tools lean sigma yang dipakai pada penelitian ini adalah Value Stream Mapping, pareto chart, fishbone diagram, dan Failure Mode and Effect Analysis. Dari hasil penelitian diperoleh waste terkritis yaitu waste defect, waste motion, dan transportation dan waste waiting pada proses produksi disc, rim, ring, assy, dan paint. Dalam penelitian ini jenis waste defect tertinggi adalah dimensi part tidak sesuai pada proses expanding yang terdapat pada proses produksi rim dengan jumlah defect 1900 unit. Dan waste transportation adalah jarak antara proses assy dengan proses paint sejauh 100 m. Dengan perbaikan ini diharapkan dapat menyelesaikan masalah yang berkaitan dengan meminimalisasi terjadinya waste defect, waiting, motion, dan transportation. Kata Kunci : Waste, Lean Sigma,Value Stream Mapping, Pareto Chart, Fishbone Diagram, dan Failure Mode and Effect Analysis.

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Perancangan Perbaikan Proses Produksi Komponen Bodi Mobil Daihatsu dengan Lean Manufacturing di PT. “XYZ”

Jurnal Studi Manajemen dan Bisnis ◽

10.21107/jsmb.v5i2.6667 ◽

2020 ◽

Vol 5 (2) ◽

pp. 122-129

Author(s):

Satria Khalif Isnain ◽

Putu Dana Karningsih

Keyword(s):

Production Process ◽

Lean Manufacturing ◽

Early Observation ◽

Borda Count ◽

Value Stream Mapping ◽

Positive Signal ◽

Effect Analysis ◽

Value Stream ◽

Potential Market ◽

Product Part

Astra Daihatsu Motor Company. Potential market for automotive is continuously growing which is positive signal for automotive businesses. However nowadays competition is also getting stronger. Therefore PT Inti Pantja Press Industri should efficiently manage their production. One way is by reducing and eliminating waste in its production. Production process in PT. Inti Pantja Press Industri is still having several problems. Based on early observation there are bottleneck in subassy processes and also defective product. Reffering to these problems, it can be indicated that there are several waste in production process of PT. Inti Pantja Press Industri.Therefore, Lean Manufacturing approach is utilized to reduce or eliminate waste in production processes. First, various waste are identified using Value Stream Mapping. Borda Count Method is used for determining critical waste that occur, they are as follow: waste waiting, defect, and overproduction that cause over inventory finish product. Then, 5 Whys Analysis specifies root causes of waste waiting and waste defect. By using Failure Mode and Effect Analysis, highest priority of root causescan be selected, which are operator do not clean dies before press process, operator do not replace components that has already over its lifetime (wear) and rust on finish product part. Recommendations for improvements are conducted by implementating Poka Yoke method, they are: installation of sensors and equipment in Press machines and wrapping finish part product.

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Implementation of Lean Manufacturing and Waste Minimization to Overcome Delay in Metering Regulating System Fabrication Process using Value Stream Mapping and VALSAT Method Approach (Case Study: Company YS)

International Journal of Advanced Technology in Mechanical, Mechatronics and Materials ◽

10.37869/ijatec.v2i1.41 ◽

2021 ◽

Vol 2 (1) ◽

pp. 22-34

Author(s):

Adizty Suparno ◽

Muhammad Kholil ◽

Farichatus Sa’diyah ◽

Sulaiman Bin H Hasan

Keyword(s):

Natural Gas ◽

Lean Manufacturing ◽

Fabrication Process ◽

Value Stream Mapping ◽

Relationship Matrix ◽

Gas Network ◽

Value Stream ◽

Natural Gas Network ◽

Fishbone Diagram ◽

Future Value

Company YS participates in managing the natural gas network by creating a Metering Regulating System (MRS), which is a tool to measure gas usage and damage to the natural gas network. Based on the data obtained, the MRS delivery process was often not in accordance with the agreed schedule, there was a delay of up to 46%, namely 50 days late from the planned schedule. To overcome these delays, waste reduction is carried out by mapping the overall condition of the company in Value Stream Mapping (VSM) and mapping in detail with the Value Stream Mapping Analysis Tools (VALSAT). In the VSM method, a Current Value Stream Mapping is carried out which then identifies the waste in which the correlation score between the wastes is described in a matrix called the Waste Relationship Matrix then followed by the calculation of the Waste Assessment Questionnaire. Then in the VALSAT method, further waste identification was carried out using seven tools. The most influential percentage of waste that has been obtained is then searched for the root cause using a fishbone diagram and then eliminated and depicted in the Future Value Stream Mapping. The most influential waste in the fabrication process is Waiting and after repairs according to the recommendations, the lead time is obtained from 41,822.60 minutes or 99 working days to 35,055.60 minutes or 83 working days so that the fabrication process can be completed 3 days faster than scheduled.

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Kanban and value stream mapping analysis in lean manufacturing philosophy via simulation: a plastic fabrication (case study)

International Journal of Services and Operations Management ◽

10.1504/ijsom.2015.065977 ◽

2015 ◽

Vol 20 (1) ◽

pp. 118 ◽

Cited By ~ 4

Author(s):

Mahdi Sabaghi ◽

Reza Rostamzadeh ◽

Christian Mascle

Keyword(s):

Lean Manufacturing ◽

Value Stream Mapping ◽

Value Stream ◽

Mapping Analysis

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Usulan Perbaikan untuk Pengurangan Waste Pada Proses Produksi dengan Metoda Lean Manufacturing

Jurnal PASTI ◽

10.22441/pasti.2019.v13i2.008 ◽

2019 ◽

Vol 13 (2) ◽

pp. 187

Author(s):

Rini Fitriyani ◽

Sahril Saifudin ◽

Kesyah Margareta

Keyword(s):

Failure Mode ◽

Lean Manufacturing ◽

Fault Tree ◽

Fault Tree Analysis ◽

Plasma Welding ◽

Effect Analysis ◽

Tree Analysis ◽

Mode Effect ◽

Failure Mode Effect Analysis

Penelitian ini membahas tentang usulan perbaikan untuk pengurangan waste pada proses produksi dengan metoda lean manufacturing. Dalam penelitian ini dihasilkan waste yang paling dominan terdapat pada lini produksi saxophone dengan total skor 3 yaitu defect, dan unnecessary motion dan unnecessary transportation dengan masing – masing skor 2. Sedangkan faktor penyebab yang mempengaruhi pemborosan dapat diketahui dengan menggunakan fault tree analysis ( FTA ) dimana pada waste defect penyebab dasar terjadinya waste adalah hanya ada 2 operator buffing, human eror dan belum adanya jadwal penggantian kompon secara berkala. Sedangkan pada waste unnecessary motion penyebab waste adalah lot keranjang cuci hanya muat 5 pcs dan tidak ada meja untuk operator melakukan pemindahan material. Dan pada waste unnecessary transportation penyebab waste adalah human eror yaitu operator yang mengobrol dan lamanya waktu transportasi yang disebabkan oleh tata letak mesin yang berjauhan. Sedangkan hasil dengan menggunakan metode failure mode effect analysis ( FMEA ) dipilih 3 tindakan yang memiliki nilai RPN paling tinggi. Dimana usulan perbaikan yang terpilih adalah perubahan layout dengan mendekatkan proses plasma welding dengan seam roller, menambah kapasitas keranjang cuci sehingga dapat meminimasi terjadinya gerakan yang berulang pada transportasi, dan menjadwalkan penggantian kompon buffing secara berkala untuk meminimasi kompon yang mengelupas dan menemple pada part karena sudah usang.

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An Application of Lean Manufacturing Techniques in Paint Manufacturing Company: A Case Study

Journal of King Abdulaziz University-Engineering Sciences ◽

10.4197/eng.28-2.5 ◽

2017 ◽

Vol 28 (1) ◽

pp. 51-73 ◽

Cited By ~ 1

Author(s):

Ahmed M. Badeeb Ahmed M. Badeeb

Keyword(s):

Lean Manufacturing ◽

Value Stream Mapping ◽

Work Place ◽

Manufacturing Companies ◽

Pareto Chart ◽

Value Stream ◽

Manufacturing Company ◽

Fishbone Diagram ◽

Manufacturing Techniques ◽

Waste Handling

As a result of the recession in Saudi Arabia, the manufacturing companies start thinking to reduce the operational cost and increasing the productivity through lean manufacturing principles. This paper is focused on increasing the productivity of a paint manufacturing company through implementing some of the lean manufacturing techniques. First, Value stream mapping analysis carried on throughout the manufacturing process and the areas of improvements in the company has been identified using fishbone diagram. Second, Work Place Organization (5S), Single Minute Exchange of Dies (SMED), Work Standardization and Kanban are the lean manufacturing techniques selected to solve different problems facing the company in these areas of improvements. A systematic approach of each technique implemented to measure its effect on the company productivity. It is observed that, applying (5S) and (SMED) techniques in the filling process decreased the changeover time by 59% and increased the daily productivity. Pareto chart recommended using work standardization in the charging process led to reduce the defects batches by 57%. Kanban system eliminated the shortages of semi-finish product and increased the output of the pre-weighing batches by 57%. In addition, overtime hours reduced by 77% and waste handling reduced by 85% and 53% for the non-hazardous and hazardous waste respectively

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