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).

scholarly journals Usulan Peningkatan Efisiensi Keseimbangan Lini Dengan Value Stream Mapping Dan Yamazumi Chart Pada PT.PAI

Jurnal METRIS ◽  
2021 ◽  
Vol 20 (1) ◽  
pp. 33-44
Author(s):  
Iphov K. Sriwana ◽  
Kurniawan Kurniawan
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Relationship Matrix ◽  
Value Stream ◽  
Second Stage ◽  
Current Value ◽  
Assessment Questionnaire ◽  
Is Value ◽  
Sports Shoes

PT. PAI is a footware company that produces sports shoes. The production process at PT. PAI, has a waste of 15.891%. To overcome the problems that occur, this study was conducted with the aim of identifying and proposing waste elimination. The method used is a lean manufacturing approach. One of the tools used is Value Stream Mapping (VSM) and Yamazumi Chart. The first stage to solve the problem is the identification of waste using the Waste Relationship Matrix (WRM), Waste Assessment Questionnaire (WAQ) and VALSAT. The second stage is carried out by designing the current Value Stream Mapping (VSM), designing the proposed improvements using the Yamazumi Chart to balance the production line and designing the Future VSM based on the results of the proposals that have been given. The result of identification using these tools is known that the biggest waste is waste in the process with a percentage of 15.891% followed by overproduction of 15.774%. Based on the calculation using VSM and Yamazumi Chart, elimination of waste can be done as much as 5.48%, reducing the number of workers by 32 people and reducing the number of work stations by 16 work stations

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

JUMINTEN ◽  
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.

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).

The Development and Implementation Lean Manufacturing in Indonesian Furniture Industry

2015 ◽  
Vol 815 ◽  
pp. 258-263 ◽  
Author(s):  
Bambang Suhardi ◽  
Akiyumas Sahadewo ◽  
Pringgo Widyo Laksono
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Analysis Tool ◽  
Furniture Industry ◽  
Value Stream ◽  
Initial Identification ◽  
Export Industries

This research discusses about the principles of lean manufacturing in furniture export industries. The aim of this research is to improve productivity by reducing waste which exists in the production floor. This research discusses about the implementation of Value Stream Mapping (VSM) as waste initial identification instrument, standardization work, and Single Minute Exchange of Die (SMED) as an analysis tool and improvement implementation. Both of that methods are conducted in this research. This research is practically applicable and proven to be able to reduce waste which exists in production floor and to improve the factory’s productivity.

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

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.

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 IMPLEMENTASI LEAN MANUFACTURING PADA PROSES PRODUKSI UNTUK MENGURANGI WASTE GUNA LEBIH EFEKTIF DAN EFISIEN

2020 ◽  
Vol 1 (2) ◽  
pp. 85-95
Author(s):  
Edwin Bayu Kurniawan ◽  
Ni Luh Putu Hariastuti
Keyword(s):  
Failure Mode ◽  
Lean Manufacturing ◽  
Effect Analysis ◽  
Value Stream ◽  
Analysis Tools ◽  
Industrial Coating ◽  
Cycle Efficiency

CV. Nipson Industrial Coating adalah perusahaan yang hanya bergerak untuk memproduksi coating, dimana perlu terus menerus meningkatkan kinerja perusahaan untuk meningkatkan kualitas dan tepat waktu dalam pengiriman ke pada konsumen. Dengan strategi lean manufacturing perusahaan mampu mengidentifikasi jenis pemborosan (waste) yang terjadi dalam proses produksi sehingga waste yang terjadi bisa dihilangkan. Pemborosan (waste) diidentifikasi dengan seven waste, kemudian dilakukan pemetaan secara detail dengan Value Stream Analysis Tools (VALSAT) dan dianalisa akar penyebab masalah dengan Failure Mode and Effect Analysis (FMEA). Dari hasil penelitian ini, didapatkan pemborosan (waste) pada proses produksi adalah waiting/delay dan defect. Dampak dari penerapan strategi lean manufacturing pada proses produksi menurut process activity mapping, meningkatkan process cycle efficiency menjadi 94.84% dan menurut quality filter mapping adalah melaksanakan standarisasi pada material bahan baku kemudian melakukan pelatihan terhadap pekerja dikhususkan terhadap bidangnya masing-masing.  Kata Kunci : Lean Manufacturing, Waste, VSM, VALSAT, FMEA

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

2021 ◽  
Vol 10 (1) ◽  
pp. 89-100
Author(s):  
Suparno Suparno ◽  
Agus Selamet Susanto
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Leaf Spring ◽  
Effect Analysis ◽  
Productivity Level ◽  
Value Stream ◽  
Mode Effect ◽  
Mapping Analysis ◽  
Fishbone Diagram ◽  
Failure Mode Effect Analysis

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

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

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.

scholarly journals 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)

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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