Implementation of lean manufacturing to enhance the efficiency of acrylic resins production process

High lead time processing of acrylic resins leads to the production of products to consumer undergoes and high-production costs. This study aims to reduce lead time by analyzing various activities that have value-added, non-value-added, and necessary non-value-added. The research is conducted using lean manufacturing approaches on acrylic resin production processes. The analysis shows that the activity of delay and transportation is a contributor of waste that occurs in the production process of acrylic resins. Improvements by minimizing both activities in the are thining tank, reactor, and monomer tank can increase the efficiency of the production process. The improvement results show a decrease in lead time from 1298 minutes to 1075 minutes. This study demonstrates that lean manufacturing can improve the time process efficiency of 17.18%, which means the output ratio will increase by around 17.18% in a process.

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Penerapan Lean Manufacturing untuk Mengurangi Waste pada Produksi Absorbent

Jurnal INTECH Teknik Industri Universitas Serang Raya ◽

10.30656/intech.v4i1.854 ◽

2018 ◽

Vol 4 (1) ◽

pp. 23 ◽

Cited By ~ 1

Author(s):

Agung Ravizar ◽

Rosihin Rosihin

Keyword(s):

Production Process ◽

Lean Manufacturing ◽

Quantitative Data ◽

Lead Time ◽

Historical Data ◽

Mapping Method ◽

Production Costs ◽

Value Stream Mapping ◽

Value Stream ◽

Process Speed

This study aims to reduce the waste that occurs on each workstation and has an impact on increasing productivity and reducing production costs caused by waste that occurs during production. The data used for this study is quantitative data obtained by direct observation to the relevant departments regarding the problem of identifying waste that occurs — data taken from observations as much as 30 times the collection of data and historical data used from January 2016 to June 2017. By using the value stream mapping method on lean manufacturing, it can be seen that there are five types of waste from the existing seven waste. The five wastes are unnecessary motion, waiting, reject, transportation and in-process processes. From the results of the value stream mapping carried out a reduction in waste on each workstation with a total reduction of waste that occurs at 66.97 tons / year or 18.6% on waste gel and 88.8 tons / year or 19.3% at waste powder and there was a reduction in the changeover process for 45 minutes or 12.16% of the total changeover time before the improvement. Also, there was also an increase in the production process speed of 2 minutes 47 seconds or 4.52% from the lead time of the previous production process, 61 minutes 34 seconds to 58 minutes 47 seconds.

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Analisis Penerapan Lean Manufacturing untuk Menghilangkan Pemborosan di Lini Produksi PT Adi Satria Abadi

Jurnal Rekayasa Sistem Industri ◽

10.26593/jrsi.v4i1.1383.47-54 ◽

2017 ◽

Vol 4 (1) ◽

pp. 47 ◽

Cited By ~ 2

Author(s):

Muhammad Shodiq Abdul Khannan ◽

Haryono Haryono

Keyword(s):

Production Process ◽

Lean Manufacturing ◽

Lead Time ◽

Value Added ◽

Assessment Model ◽

Value Stream Mapping ◽

Flow Process ◽

Value Stream

Productivity achievement at PT Adi Satria Abadi (Golf Gloves Division) is not optimal because of the waste. Value Stream Mapping as a Lean Manufacturing tool is used to map the production process and identify and eliminate the waste. The advantage of VSM is its capability to give visual map of value added flow process, necessary but non value added flow process, and non value added flow process. In this study Waste Assessment Model (WAM) also have been implemented to identify the waste. The sequence of three greatest waste are Defect/Reject 24,73%, Unneccessary Inventory 18,80%, and Unneccessary Motion 15,44%. This study can reduce production lead time 62,22 minutes and improve the production throughput by 77 pcs.

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Pendekatan Lean Manufacturing dalam Proses Produksi Kerajinan Bordir Sulaman dengan Metode Manajemen Berbasis Aktivitas

Talenta Conference Series Energy and Engineering (EE) ◽

10.32734/ee.v2i4.647 ◽

2019 ◽

Vol 2 (4) ◽

Author(s):

Anizar ◽

A. Rahim Matondang ◽

Hamida Hasan ◽

Delilah Mentari

Keyword(s):

Production Process ◽

Continuous Improvement ◽

Cost Efficiency ◽

Lean Manufacturing ◽

Business Management ◽

Production Costs ◽

Production Waste ◽

Total Production ◽

Production Output ◽

Domestic Products

Sulam bayangan merupakan produk sektor kreatif yang berkontribusi bagi produk domestik bruto namun menuntut efisiensi dan efektivitas untuk memenangkan persaingan antar pelaku usaha. Efisiensi akan mengurangi waste aktivitas produksi dan mengurangi biaya produksi yang dibutuhkan. Pada proses produksi kerajinan sulam bayangan masih terdapat waste berupa aktivitas yang tidak bernilai tambah yang berpengaruh terhadap output produksi. Permasalahan tersebut dapat diselesaikan dengan pendekatan lean manufacturing untuk menciptakan continuous improvement pada proses produksi dengan metode Activity Based Management (ABM). Penerapan ABM menciptakan efisiensi biaya yang menekankan pengelolaan bisnis berdasarkan aktivitas. Perbaikan yang dilakukan yaitu eliminasi dan penggabungan elemen kerja pemeriksaan motif dan sulaman. Hasilnya adalah efisiensi biaya produksi sebesar 4,89% dan waktu produksi sebesar 6,07%. Shadow embroidery is a creative sector product that contributes to gross domestic products but requires funds and assistance to win competition among companies. Efficiency will reduce production waste and reduce the required production costs. In the process of producing shadow embroidery craft it is still a waste containing activities that are not added added to the production output. These problems can be discussed with lean manufacturing to create continuous improvement in the production process with the Activity Based Management (ABM) method. Implementation of AB Creating cost efficiency that governs business management based on activity. The improvements made are elimination and incorporation of work elements to examine motifs and embroidery. Total production costs amounted to 4.89% and production costs amounted to 6.07%.

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Peningkatan Produksi Minyak Sereh Wangi Pada Penyulingan Minyak Sereh Wangi Di Desa Cimungkal-Sumedang

ETHOS (Jurnal Penelitian dan Pengabdian) ◽

10.29313/ethos.v0i0.2247 ◽

2017 ◽

pp. 105

Author(s):

Nugraha Nugraha

Keyword(s):

Production Process ◽

Lead Time ◽

Value Added ◽

Oil Refinery ◽

Oil Refining ◽

Value Stream Mapping ◽

Value Stream ◽

Citronella Oil ◽

Alternative Measures ◽

The Village

Inability to fulfill the demand of consumers is becoming the major issues on citronella oil refinery in the village of Cimungkal Sumedang. This study was conducted to formulate alternative measures in order to increase the production of citronella oil distillates in the Cimungkal village. Mapping of the production process is done with Value Stream Mapping (VSM) as a first step to determine the processing time (lead time of production) and identify the waste that occurs, analyze the causes of the problems at the manufacturing level, and formulate remedial measures to increase the production of oil of citronella. The results show some activity in the production process of citronella oil which is a waste and should be minimized. By mapping, it can be seen that the lead time citronella oil refining initial amounted to 647 minutes or 10.78 hours. After repairs (Future State) improvements Total lead time to 274 minutes. Value-added activity increased by 38.93%, non-value added decreased by 3.63%, and necessary but non-value added fell by 35.3%. The study also resulted in the formulation of strategies that can be done to increase the production of oil of citronella.

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USULAN PENERAPAN LEAN MANUFACTURING UNTUK MENGIDENTIFIKASI DAN MENGURANGI WASTE (STUDI KASUS PADA PT.X)

JURNAL TEKNIK INDUSTRI ◽

10.25105/jti.v7i3.3139 ◽

2018 ◽

Vol 7 (3) ◽

Author(s):

Fenny Joyanti Amanda ◽

Carla Olyvia Doaly

Keyword(s):

Lean Manufacturing ◽

Lead Time ◽

Value Added ◽

Current State

PT. X adalah perusahaan yang bergerak di bidang produksi kapur barus, anti bau, dan serap air. Dalam pelaksanaannya, perusahaan perlu untuk terus meningkatkan kinerja produktivitas, kualitas, ketepatan waktu dalam pengiriman, serta berusaha menurunkan biaya. Untuk mencapai tujuan tersebut perusahaan perlu mengetahui aktivitas apa saja yang memberikan value added bagi produk, serta pemborosan apa saja yang sering terjadi dalam proses produksi. Oleh karena itu diperlukan suatu pendekatan lean manufacturing. Dengan strategi lean, perusahaan diharapkan mampu meningkatkan rasio value added produk serta mengurangi pemborosan. Pemahaman kondisi aktual perusahaan digambarkan dalam Current State Mapping. Pemborosan diidentifikasikan dengan delapan waste, kemudian dilakukan pembobotan secara detail dengan waste relationhip matrix (WRM) dan waste assessment quetionaire (WAQ). Setelah didapatkan hasil, dilakukan pemilihat tools dengan bantuan VALSAT dan dianalisa akar penyebab permasalahannya. Berdasarkan pengolahan data didapatkan 2 skor rata-rata tertinggi yaitu motion (21%), Defect (17.93%). Skor rata-rata pemborosan tersebut dikalikan dengan faktor pengali detail mapping, sehingga didapatkan detail mapping tools yang dominan adalah Process Activity Mapping (35.23%). Lead time dalam produksi kapur barus adalah 5127.36 menit, setelah usulan perbaikan dilaksanakan didapatkan lead time sebesar 1832.77 menit, dengan cara mengurangi waktu gerakan pada proses produksi dan pada defect dilakukan perbaikan SOP.

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Penerapan Lean Manufacturing Untuk Mengidentifikasi Dan Menurunkan Waste (Studi Kasus CV Tanara Textile)

JURNAL TEKNOLOGI DAN MANAJEMEN INDUSTRI ◽

10.36040/jtmi.v5i1.251 ◽

2019 ◽

Vol 5 (1) ◽

pp. 1-7

Author(s):

Catur Kusbiantoro ◽

Ellysa Nursanti

Keyword(s):

Lean Manufacturing ◽

Lead Time ◽

Value Added ◽

Value Stream Mapping ◽

Value Stream ◽

Work In Process ◽

Cycle Efficiency

CV. Tanara Textile merupakan salah satu perusahaan tekstil yang termasuk dalam kelompok industri penyempurnaan kain berupa kain kaos. Pada proses produksi di perusahaan masih ditemukan beberapa waste. Penelitian ini bertujuan untuk mengidentifikasi dan menurunkan waste yang terjadi pada proses produksi maka digunakan pendekatan lean manufacturing. Metode Value Stream Mapping (VSM) digunakan untuk pemetaan aliran produksi dan aliran informasi terhadap suatu produk pada tingkat produksi total, melakukan wawancara untuk pembobotan penyebab 7 waste yang sering terjadi pada proses produksi, VALSAT untuk menganalisa pemborosan dari hasil pembobotan yang selanjutnya melakukan detailed mapping tools, serta analisis FMEA untuk mengetahui penyebab kegagalan prosesyang terjadi di lini produksi lalu menghitung nilai RPN tertinggi. Selanjutnya melakukan usulan perbaikan untuk menurunkan waste unnecessary inventory serta menganalisis perbaikan secara berkelanjutan dengan PDCA. Waste terbesar ada pada Unncessary Inventory sebesar 28,571% faktor penyebabnya adalah penumpukan bahan baku, work in process (WIP), sparepart yang tidak terpakai dan penimbunan pada finished goods Sebelum perbaikan proses produksi 16 hari 9 jam dimana Value Added 6 hari 4 jam dan Lead Time 10 hari 4 jam, setelah perbaikan proses produksi menjadi 14 hari 5 jam dimana Value Added 6 hari 4 jam dan Lead Time 8 hari 1 jam, dengan demikian dapat meningkatkan process cycle efficiency sebesar 17,19% dan menghemat lead time sebesar 2,546% dengan penurunan waste sebesar 8,31%

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Application of Lean Tool (Value Stream Mapping) in Minimisation of the Non-Value Added Waste (A Case Study of Tractor Industry)

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.110-116.2062 ◽

2011 ◽

Vol 110-116 ◽

pp. 2062-2066 ◽

Cited By ~ 1

Author(s):

Paramdeep Singh ◽

Harpuneet Singh

Keyword(s):

Lean Manufacturing ◽

Lead Time ◽

Manufacturing System ◽

Research Work ◽

Value Added ◽

Value Stream Mapping ◽

Value Stream ◽

Work In Process ◽

Before And After ◽

Traditional Manufacturing

Lean manufacturing has been proved to be an effective management philosophy for improving businesses in a competitive market by eliminating non-value added waste and improving in process operations. Value stream mapping is an important tool used to identify the opportunities for various lean techniques. The present research mainly focuses on the description of a model that is developed to contrast the “before” and “after” scenarios in detail in order to obtain the various benefits such as reduced production lead time, lower work in process inventory [1] and proper utilisation of the workforce. The current manufacturing system has been compared with the proposed pull (Kanban) system which shows the benefits of the proposed lean manufacturing system over the existing traditional manufacturing system. The present research work has been carried out at typical tractor industry which shows 50.5% reduction in total lead time in the future state value mapping of the crank case and the number of operators involved in processing of crank case has also been reduced from 22 to 18.

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Improvement of Artistic Cast Production System

Archives of Foundry Engineering ◽

10.1515/afe-2017-0107 ◽

2017 ◽

Vol 17 (3) ◽

pp. 143-148

Author(s):

R. Władysiak ◽

T. Pacyniak ◽

J. Trzoska

Keyword(s):

Production Process ◽

Production System ◽

Lean Manufacturing ◽

Production Costs ◽

Value Stream Mapping ◽

Value Stream ◽

Current State ◽

Production Improvement ◽

Cast Production ◽

Lower Production

AbstractThe paper presents the technology and organization of the artistic cast production. On the basis of the actual cast production system, the manufacturing process was shown, in particular sand–piece moulding, which is a very important process and a time-consuming part of the entire manufacture of the casts. The current state of the production process as well as the organization of the work and production technology were analysed with the use of methods and techniques of production improvement, the Lean Manufacturing concept and computer systems. The results of the analysis and studies were shown with use of schemes and graphs of the layout of the production resources, a flow chart of the production process, value stream mapping, and a costs table for the production and modernization of the moulding stage. The work has shown that there are possibilities to improve the artistic cast production system. This improvement leads to increased productivity, lower production costs of artistic casts and increased competitiveness of the foundry.

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Analisis Penerapan Lean Production Process untuk Mengurangi Lead Time Process Perawatan Engine (Studi Kasus PT.GMF AEROASIA)

Jurnal Optimasi Sistem Industri ◽

10.25077/josi.v14.n2.p299-309.2015 ◽

2016 ◽

Vol 14 (2) ◽

pp. 299 ◽

Cited By ~ 2

Author(s):

Wahyu Adrianto ◽

Muhammad Kholil

Keyword(s):

Lean Manufacturing ◽

Lead Time ◽

Value Added ◽

Value Stream Mapping ◽

Dominant Type ◽

Value Stream ◽

Root Cause ◽

Gate System ◽

People Development ◽

Engine Maintenance

Engine maintenance strives to always improve its service excellence with tools such as gate system where the system is expected to realize the lead time for 60days. In the implementation of the gate system is still not able to meet the expected target. During maintenance or overhaul the engine is still encountered waste or waste that causes the target cannot be met. Lean Manufacturing is an approach that aims to minimize waste that occurs in the process flow.Understanding the conditions of the process described in Value Stream Mapping for further elaborate activities that have the value-added and non-value added.Through seven waste concept, then be weighted to determine the most dominant type of waste.From the data processing is obtained that through the Value Stream Mapping is known gate 1 and gate 3 is the point that there are many wastes. Weighting and ranking of seven existing waste in the process of the activity obtained results in the form of a waste critical sequence of seven existing waste. Highest weights on the type of waste waiting with a weight of 0.38. Results of Root Cause Analysis in mind that the root cause of waste waiting for that data is maintained, the lack of attention to people development, There are still bugs in the system and miscommunication.

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ANALISIS AGROINDUSTRI LEMPUK DURIAN DI DESA SELATBARU KECAMATAN BANTAN KABUPATEN BENGKALIS

DINAMIKA PERTANIAN ◽

10.25299/dp.2019.vol35(2).7696 ◽

2021 ◽

Vol 35 (2) ◽

pp. 93-106

Author(s):

Dora Felicita Dongoran ◽

Sisca Vaulina

Keyword(s):

Production Process ◽

Raw Materials ◽

Survey Methods ◽

Economic Value ◽

Value Added ◽

Production Costs ◽

Added Value ◽

Small Scale ◽

Net Income ◽

Supporting Materials

Agroindustry is an activity of processing agricultural products to be semi-product or product that has economic value. The purpose of this study was to determine the characteristics of entrepreneurs and agroindustry business profiles of lempuk durian, the use of raw materials, supporting materials, labor, processing technology, and production processes of lempuk durian, the poduction costs, income, efficiency and added value of lempuk durian, and marketing of durian products. The study used survey methods located in Selatbaru Village, Bantan District, Bengkalis Regency, Riau Province. A total of 4 craffsmen was selected as respondents by the census. The data were analyzed by qualitative descriptive and quantitative descriptive approaches. The results showed that the lempuk durian craffsman averaged 47 years old, 12 years old education, 14 years of business experience, and 5 person of family member. Agroindustry profile of lempuk durian was a small-scale industry category. The use of raw materials consisted of durian meat and supporting materials such as sugar, firewood, plastic packing, bunch, string, label, isolation, solar, and gas cylinders. The average use of fixed costs was IDR 1,968,633 per production process, production costs was IDR 15,886,133 per production process, gross income was IDR 26,937,500 per production process and net income was IDR 11,051,367 per production process and RCR value was 1.70 with value-added IDR 51,016. The marketing of lempuk durian had two marketing channels.

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