scholarly journals Peningkatan Efisiensi Proses Produksi Benang dengan Pendekatan Lean Manufacturing Menggunakan Metode WAM dan VALSAT di PT. XYZ

Jurnal IPTEK ◽  
2020 ◽  
Vol 4 (1) ◽  
pp. 27-32
Author(s):  
Gian Restuningtias ◽  
Ni Made Sudri ◽  
Yenny Widianty
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Assessment Model ◽  
Value Stream ◽  
Analysis Tools

PT. XYZ adalah perusahaan manufaktur yang bergerak di bidang produksi pembuatan benang. Salah satu produk yang dihasilkan yaitu benang P100 (Polyester 100%). Permasalahan yang dihadapi perusahaan adalah berlebihnya target produksi disebabkan karena adanya aktivitas yang tidak bernilai tambah (waste). Untuk itu digunakan pendekatan lean manufacturing untuk mengurangi waste pada proses produksi benang ini. Metode yang digunakan adalah Waste Assessment Model (WAM) untuk mengidentifikasi waste yang dominan pada proses pembuatan benang P100 (Polyester 100%) dan Value Stream Analysis Tools (VALSAT) untuk memilih detail mapping tools. Berdasarkan hasil pengolahan, diperoleh waste yang paling dominan adalah overproduction, inventory, dan motion. Rekomendasi perbaikan yang diberikan yaitu penambahan alat bantu (handtruck) pada pengambilan sliver di proses drawing , penambahan operator pada proses winding, melakukan forecasting untuk mengurangi waste overproduction, menerapkan metode pengendalian persediaan untuk mengurangi waste inventory, dan melakukan penukaran tata letak ruang QC dengan ruang shift untuk mengurangi waste motion. Hasil evaluasi rekomendasi diperoleh penurunan lead time dari 133,13 menit menjadi 115,13 menit dan usulan perbaikan ini meningkatkan nilai PCE dari 48,85% menjadi 56,46%. Kata kunci  : Lean Manufacturing, Waste, WAM , VALSAT ,  Lead Time, PCE

scholarly journals IMPLEMENTASI KONSEP LEAN MANUFACTURING GUNA MENGURANGI PEMBOROSAN DI LANTAI PRODUKSI

OPSI ◽  
2018 ◽  
Vol 11 (1) ◽  
pp. 14 ◽  
Author(s):  
Almer Panji Pradana ◽  
Mochammad Chaeron ◽  
Muhammad Shodiq Abdul Khanan
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Assessment Model ◽  
Value Stream ◽  
Event Simulation ◽  
Analysis Tools ◽  
Big Picture

CV Marga Jaya (Pabrik II) adalah perusahaan yang bergerak di bidang pembuatan paving/conblock secara masal. CV Marga Jaya (Pabrik II) selalu berusaha mengurangi pemborosan yang terjadi selama proses produksi paving/conblock. Pemborosan yang terjadi antari lain, adanya produksi berlebih, transportasi, waktu menunggu, dan cacat yang berlebih.  Lean Manufacaturing merupakan pendekatan yang bertujuan untuk merampingkan proses dengan mengurangi pemborosan yang terjadi selama proses produksi. Pendekatan konsep lean manufacturing dimulai dengan membuat big picture mapping, dilanjutkan dengan waste assessment model (WAM), diagram cause and effects, value stream analysis tools (VALSAT), usulan perbaikan waste yang terjadi, dan pembuatan descrete event simulation (DES). Hasil yang didapat bahwa waktu menunggu yang terjadi diperbaiki dengan menggunakan conveyor, produksi berlebih yang terjadi diperbaiki dengan melakukan perencanaan produksi, dan cacat berlebih yang terjadi diperbaiki dengan menggunakan 5W+1H dengan sebelumnya menggunakan konsep lean six sigma dan didapat nilai sigma sebesar 4,31 sigma. Simulasi proses menunjukkan dengan mengurangi pemborosan, kemampuan produksi naik 15,36% (penjemuran 30 hari) dan 147,20% (penjemuran 7 hari).

scholarly journals WASTE ELIMINATION USING VALUE STREAM MAPPING AND VALSAT

2017 ◽  
Vol 3 (2) ◽  
Author(s):  
Dion Avellino Suyanto ◽  
Sunday Noya
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Analysis Tools ◽  
Fierce Competition ◽  
Cycle Efficiency ◽  
Working Efficiency

Fierce competition encourages companies to make continuous improvements to achieve better working efficiency. One method to improve the working efficiency is using the concept of lean manufacturing. The efficiency of the existing work in PT. Rimba Kencana is still not good because there are many processes that are not uniform and because of that, production lead time is increased. By using value stream mapping and value stream analysis tools (VALSAT), the production processes in the company are mapped into the current state mapping and future state mapping. In the current state mapping, the total value of production lead time is 59.49 days and the value of process cycle efficiency (PCE) is 0.013%. After doing improvement on welding department, the total value of production lead time decreased to 48.22 days and the value of process cycle efficiency becomes 0.016%. Keywords: Efficiency, Value Stream Mapping, Value Stream Analysis Tools

scholarly journals The Lean Manufacturing Implementation to Eliminate Waste in Machining Cast Wheel Line Production by Using WAM dan VALSAT Method

2021 ◽  
Vol 2 (1) ◽  
pp. 56-62
Author(s):  
Daonil ◽  
Yuri M. Zagloel
Keyword(s):  
Lean Manufacturing ◽  
Assessment Model ◽  
Leak Test ◽  
Line Production ◽  
Value Stream ◽  
Analysis Tools

Penelitian ini bertujuan untuk mengeliminasi waste pada lini produksi machining cast wheel dengan implementasi konsep lean manufacturing. Metode lean manufacturing yang digunakan adalah Waste Assessment Model (WAM) untuk identifikasi waste pada proses manufaktur dan Value Stream Analysis Tools (VALSAT) untuk memilih mapping tools yang digunakan dalam analisis waste. Berdasarkan hasil analisis didapatkan tiga rekomendasi perbaikan yaitu modifikasi desain soft jaw mesin OP 20 (facing dan boring), aplikasi metode sampling pada proses OP 40 (leak test), dan penggabungan proses OP 70/OP 60 (washing). Hasil evaluasi rekomendasi didapatkan perbaikan pada lini produksi machining cast wheel berupa peningkatan kapasitas produksi menjadi 1,350 set per hari, penurunan reject rate menjadi 2%, dan efisiensi man power sebanyak 3 orang

scholarly journals Perancangan Lean Manufacturing dengan Menggunakan Waste Assessment Model (WAM) dan VALSAT untuk Meminimumkan Waste (Studi Kasus: PT. XYZ)

2018 ◽  
Vol 7 (1) ◽  
pp. 55
Author(s):  
Tamzil Satria
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Research Result ◽  
Value Added ◽  
Assessment Model ◽  
Production Time ◽  
Value Stream ◽  
Tea Production ◽  
Cycle Efficiency ◽  
Industrial Company

<p><em>As an industrial company, XYZ Ltd. engaged in beverages should pay attention to the detailed processes of each line of its production. This aims to minimize potential problems which may occur that can cause losses. This research aimed to minimize waste on the production floor by designing  lean manufacturing. Lean manufacturing is an approach that tries to eliminate waste that occurs in the value stream. The method used is Waste Assessment Model (WAM) that functions to identify waste in tea  production, and Value Stream Analysis Tools (VALSAT) which functions to select mappingtools used, based on WAM result. From the research result, it was found out  that the production time of original tea 450 ml took 20,255.4 seconds and the total lead time of product fulfillment for delivery to customers took 13.23 days. The average reject product was 0.65%, exceeding the company maximum standard. Based on the mapping, recommendation for improvement was  given to minimize waste, among others the elimination of Non Value Added (NVA) activity, the application of forecasting, and preventive maintenance activities. This research resulted in the waste identification, which  the biggest waste in this company was defect, decreasing the lead time of production time to become 14,767,4 second faster and Process Cycle Efficiency (PCE) which was increased from 39,12% to 53,66%.</em></p>

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

2017 ◽  
Vol 4 (1) ◽  
pp. 47 ◽  
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<br />the waste. Value Stream Mapping as a Lean Manufacturing tool is used to map the production process<br />and identify and eliminate the waste. The advantage of VSM is its capability to give visual map of value<br />added flow process, necessary but non value added flow process, and non value added flow process. In this<br />study Waste Assessment Model (WAM) also have been implemented to identify the waste. The sequence of<br />three greatest waste are Defect/Reject 24,73%, Unneccessary Inventory 18,80%, and Unneccessary Motion<br />15,44%. This study can reduce production lead time 62,22 minutes and improve the production throughput<br />by 77 pcs.

scholarly journals MEMINIMASI PEMBOROSAN DENGAN LEAN MANUFACTURING PADA PROSES PRODUKSI DI PT. IE

2021 ◽  
pp. 1451
Author(s):  
Ahmad Ahmad ◽  
Helena JK ◽  
Andrean Yonathan
Keyword(s):  
Waiting Time ◽  
Cycle Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Fault Tree Analysis ◽  
Value Stream Mapping ◽  
Tree Analysis ◽  
Value Stream ◽  
Current State ◽  
Future State

PT. IE is engaged in the business of making Lighting and Lampposts. Based on observations and interviews, there are still some wastes that arise in the flow of the production process, among which there are still many wastes of waiting time, transportation, movement and inventory. These wastes cause the product completion time to be longer and the resulting quality decreases. To eliminate or reduce waste, it is necessary to apply Lean Manufacturing. Lean Manufacturing is a systematic approach to eliminating waste and changing processes by identifying and reducing waste with continuous improvement and striving to create a production flow along the value stream by eliminating all forms of waste and increasing the added value of products to customers. From the Pareto diagram, it is found that transportation waste has the highest percentage of 26.21%, waiting time is 21.38%, motion waste is 19.31% and waste inventories are 15.17%. while the results of the Value Stream Mapping Current State Map mapping obtained a production lead time of 7,680 seconds and a total cycle time of 6,660 seconds and a PCE Current State Map value of 53.09%. Identify the root causes of waste using Fishbone diagrams, 5 Why Analysis, 5W+1H, Fault Tree Analysis and FMEA. After corrective actions have been taken, based on the Value Stream Mapping Future mapping there is a decrease in production lead time to 5,220 seconds and a decrease in total cycle time to 4,860 seconds and an increase in PCE Future State Map to 68.10% so that there is an increase of 15.01% which shows The company's production process has become more Lean.PT. IE bergerak dalam bisnis pembuatan Lighting dan Tiang Lampu. Berdasarkan observasi dan wawancara, masih terdapat beberapa pemborosan (waste) yang timbul di aliran proses produksi di antaranya masih banyak terjadi pemborosan-pemborosan waktu tunggu, transportasi, gerakan dan inventori. Pemborosan-pemborosan tersebut menyebabkan waktu penyelesaian produk menjadi lebih lama dan kualitas yang dihasilkan menurun. Untuk menghilangkan atau mengurangi pemborosan diperlukan adanya penerapan Lean Manufacturing.Lean Manufacturing merupakan pendekatan sistematik untuk mengeliminasi pemborosan dan mengubah proses dengan cara mengidentifikasi dan mengurangi pemborosan dengan perbaikan kontinu dan berupaya untuk menciptakan aliran produksi sepanjang value stream dengan menghilangkan segala bentuk pemborosan serta meningkatkan nilai tambah produk kepada pelanggan. Dari diagram Pareto ditemukan waste transportasi memiliki persentase paling tinggi sebesar 26,21%, waktu tunggu  21,38%, waste motion 19,31% dan waste inventories 15,17%. sedangkan hasil pemetaan Value Stream Mapping Current State Map diperoleh production lead time selama 7.680 detik dan total cycle time selama 6.660 detik serta nilai PCE Current State Map sebesar 53,09%. Identifikasi akar permasalahan pemborosan menggunakan diagram Fishbone, 5 Why Analysis, 5W+1H, Fault Tree Analysis dan FMEA. Setelah dilakukan tindakan–tindakan perbaikan, berdasarkan pemetaan Value Stream Mapping Future ada penurunan production lead time menjadi 5.220 detik dan penurunan total cycle time menjadi 4.860 detik serta ada peningkatan PCE Future State Map menjadi 68,10% sehingga ada peningkatan 15,01% yang menunjukan proses produksi perusahaan telah menjadi lebih Lean.

scholarly journals Penerapan Lean Manufacturing untuk Mengurangi Waste pada Produksi Absorbent

2018 ◽  
Vol 4 (1) ◽  
pp. 23 ◽  
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.

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

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%

scholarly journals Waste Assessment in an Indian Casting Industry: A step towards Lean Manufacturing

2020 ◽  
Vol 9 (3) ◽  
pp. 1861-1866
Keyword(s):  
Lean Manufacturing ◽  
Assessment Model ◽  
Relationship Matrix ◽  
Analysis Tool ◽  
Effect Analysis ◽  
Value Stream ◽  
Slag Inclusions ◽  
Casting Industry ◽  
Set Up ◽  
Assessment Questionnaire

In today’s era of globalization, it is essential to ensure that Indian manufacturing industries like casting and metal-working industries which work on stringent conditions of varying customer demands and constant adhering to excellent quality standards are able to flourish in the fiercely competitive environment while keeping the production as economical as possible. Hence, the need arises for continuous improvement in the manufacturing phase of the product by assessing, minimizing, and eliminating wastes of any kind. This study adopts and implements a waste assessment model in a casting industry with the purpose of assessment of wastes and hence, proceed towards a leaner manufacturing set-up. Initially, the quantification of direct relationships between the seven types of wastes was done by forming a waste relationship matrix (WRM). Next, a waste assessment questionnaire (WAQ) consisting of 68 questions, was introduced for the allocation of wastes in the industry. The results of WRM and WAQ were integrated to obtain the ranks of the seven types of wastes in the industry, and it was found that waste of defects was the highest-ranked waste followed by wastes of inventory and overproduction. Process Activity Mapping (PAM) received the highest score (482.79) in the analysis done by Value Stream Analysis Tool (VALSAT), thus, it was chosen as the preferred tool in the current situation. The results of Failure Mode and Effect Analysis (FMEA) of various defects of casting indicated sand inclusions (432) and slag inclusions (336) as the defects having the highest Risk Priority Numbers (RPN).

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