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.

Improving Efficiency and Patient Satisfaction in a Peripherally Inserted Central Catheter Center Using Lean-Based Methodology

2014 ◽  
Vol 19 (4) ◽  
pp. 244-255 ◽  
Author(s):  
Ying Zhu ◽  
Zhenqi Lu ◽  
Hongqin Dai
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Cancer Center ◽  
Peripherally Inserted Central Catheter ◽  
Central Catheter ◽  
Value Stream ◽  
Root Cause ◽  
Number Of Patients ◽  
Future Value ◽  
Value Stream Map

Abstract Background: The peripherally inserted central catheter implantation and maintenance process was optimized at Shanghai Fu Dan University Cancer Center using lean-based methodology. Problems addressed were coping with capacity limitations and streamlining the process of patient care to reduce potential complications associated with delays in catheter administration. These clinical processes were evaluated with regard to pretreatment areas—such as booking, waiting, and patient education—and solutions were recommended to the problems that were identified. Methods: Lean methodology was used under actual clinical settings to improve the clinical process, using observations, patient surveys, interviews, data analysis, and a kaizen workshop. Three tools were applied from lean methodology: value stream mapping, bottleneck calculation, and fishbone root cause analysis. The philosophy of kaizen was used to enhance teamwork, boost morale, and encourage all members of the frontline nursing team and administration leaders to contribute ideas and suggestions for improvement. Results: A value stream map and a redesigned future value stream map were plotted at the workshop to identify problems related to inefficiency and waste and to aid in proposing solutions. Implementation of these solutions resulted in smooth and steady patient distributions on days with the largest patient volume during a typical week and an increase of 30% in the number of patients that could be seen in a week. Conclusions: The economic methodology of lean manufacturing, especially value stream mapping, can be a powerful tool for visualizing and better understanding processes to reduce waste and reengineer a standardized workstream in settings where peripheral intravenous central catheters are placed.

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

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..

scholarly journals Analisis Lean Manufacturing Pada Aktivitas Proses Produksi di PT. Mandala Logam Utama

2020 ◽  
Vol 17 (2) ◽  
pp. 59-68
Author(s):  
Yusuf Mauluddin ◽  
Ibna Faizal Rahman
Keyword(s):  
Lean Manufacturing ◽  
Theory Of Constraints ◽  
Value Stream Mapping ◽  
Relationship Matrix ◽  
Air Conditioner ◽  
Value Stream ◽  
Analysis Tools

Penelitian ini bertujuan untuk mengidentifikasi pemborosan (waste) yang ada pada aktivitas proses produksi. Pendekatan yang dilakukan adalah dengan konsep Lean Manufactuirng, tools yang digunakan adalah Value Stream Mapping (VSM), Waste Relationship Matrix (WRM) dan Waste Assessment Questionaire (WAQ), Value Stream Analysis Tools (VALSAT), waste dengan persentase terbesar direkomendasikan diperbaiki sesuai tools yang terpilih di VALSAT. Setelah hasil analisa dengan VALSAT langkah selanjutnya adalah analisa dengan TOC (theory of Constraints) sebagai alat analisa pendukung. Dari hasil penelitian ini diperoleh waste yaitu waiting yang menyebabkan overproduction pada stasiun kerja proses pendinginan, setelah terdapat hasil analisa dengan VALSAT dan TOC  maka dapat ditentukan usulan perbaikan yaitu dengan membuat gudang pendinginan khusus yang dilengkapi alat pendingin seperti AC (air conditioner) ataupun kipas angin, hal tersebut akan membantu perusahaan mengurangi waste pada aktivitas proses produksi.

scholarly journals Lean Implementation in a Manufacturing Industry through Value Stream Mapping

2019 ◽  
Vol 8 (6S) ◽  
pp. 908-913
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Present Condition ◽  
Value Stream Mapping ◽  
Lean Implementation ◽  
Value Stream ◽  
The Future ◽  
Future Value ◽  
Future Condition ◽  
Value Stream Map

Today’s market is getting progressively doused step by step, customer ending up progressively self important and hard to persuade that one will offer same value they are searching for, Lean Manufacturing has a route in front of rivalry by envisioning and upgrading the value stream. Value stream mapping (VSM) is a tool in lean execution. It is a strategy to investigate the present condition of procedure and assessing a future condition of the procedure. It takes an item or administration from its start through to end client by lessening waste contrasted with current mapping. In this paper, the first Value stream mapping of the current condition of the procedure is dissected for a situation organization and consequently, the future Value stream map was proposed base on lean standards. In light of the last outcomes, it tends to be the reason that value stream mapping is a helpful apparatus for decreasing waste and non-value included activities

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

2017 ◽  
Vol 28 (1) ◽  
pp. 51-73 ◽  
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

scholarly journals RANCANGAN USULAN PERBAIKAN UNTUK MEMINIMASI WAITING TIME PADA PROSES PRODUKSI RUBBER STEP ASPIRA BELAKANG DENGAN PENDEKATAN LEAN MANUFACTURING (STUDI KASUS: PT AGRONESIA DIVISI INDUSTRI TEKNIK KARET)

2016 ◽  
Vol 3 (02) ◽  
pp. 52
Author(s):  
Qolli Kusuma ◽  
Pratya Poeri Suryadhini ◽  
Mira Rahayu
Keyword(s):  
Waiting Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Current State ◽  
Fishbone Diagram

PT Agronesia (Divisi Industri Teknik Karet) merupakan perusahaan manufaktur industri pengolahan yang memproduksi berbagai jenis produk karet teknik untuk keperluan industri, salah satunya adalah rubber step. Penelitian ini difokuskan pada rubber step Aspira Belakang yang memiliki gap ketidaktercapaian produksi tertinggi. Pada proses produksi rubber step Aspira Belakang ditemukan waktu menunggu yang mempengaruhi tingkat pencapaian target produksi. Tahap awal dalam penelitian ini adalah dengan mengumpulkan data primer yang diolah untuk menggambarkan value stream mapping (VSM) dan process activity mapping (PAM) current state sehingga diketahui lead time dari proses produksi rubber step Aspira Belakang sebesar 5915.07 detik dengan waktu aktivitas value added sebesar 1131.47 detik atau 19.13% dari lead time. Tahap berikutnya adalah mengidentifikasi penyebab akar masalah waiting time menggunakan peta pekerja-mesin, fishbone diagram dan 5 why. Tahap selanjutnya adalah melakukan analisis 5W1H untuk memaparkan detail masalah dan menentukan rancangan usulan perbaikan menggunakan metode lean manufacturing seperti Quick Changeover dan Display. Rancangan usulan perbaikan berupa perancangan alat potong, pembagian lot pengerjaan compound, pengadaan instruksi kerja, perancangan display, pembuatan batch/stock siap cetak, dan perancangan rak penyimpanan khusus sebagai upaya dalam meminimasi waiting time pada proses produksi rubber step Aspira Belakang. Berdasarkan rancangan usulan yang diberikan didapatkan lead time sebesar 3142.10 detik dengan waktu aktivitas value added sebesar 1131.47 detik atau 36.01% dari lead time.

scholarly journals Lean Manufacturing: Waste Reduction Using Value Stream Mapping

2018 ◽  
Vol 73 ◽  
pp. 07010 ◽  
Author(s):  
Nihlah Zahrotun ◽  
Immawan Taufiq
Keyword(s):  
Lean Manufacturing ◽  
Waste Reduction ◽  
Value Stream Mapping ◽  
Order Fulfillment ◽  
Value Stream ◽  
A Value ◽  
Industry Competition ◽  
Fishbone Diagram ◽  
Medium Enterprise ◽  
The One

Cristal Sri Sujarwati is a small medium enterprise (SME) that produce keripik salak in Sleman, Yogyakarta. To survive and win industrial competition, Cristal Sri Sujarwati was required to improve its performance. But in reality there was a lot of waste in order fulfillment processes marked by ineffective and inefficient work. In this research, lean manufacturing aims to identify and eliminate waste so that the company could improve its performance in winning the industry competition. Lean manufacturing is a systematic approach used to identify and eliminate waste. This lean concept could improve responsiveness through waste reduction, continuous improvement and cost reduction. In order to identify and eliminating waste, a value stream mapping tools, waste weighting questionnaire, value stream analysis tools, and fishbone diagram are used. From the results of research, the dominant waste in the production process was waste defects, waiting, and unnecessary inventory. To eliminate waste, process activity mapping (PAM), the one of detailed mapping tools in VALSAT are used. From the results of the improvement recommendations analysis, lead time decreased by 80 minutes. From the analysis using PAM, there was a reduction of NVA activity from 3.10% to 1.01%.

scholarly journals Penerapan Lean Manufacturing Untuk Meminimasi Waste Waiting Time Pada Proses Produksi Spring Guide XXX Di CV. Gradient

2017 ◽  
Vol 4 (02) ◽  
pp. 170
Author(s):  
Kuntari Puspa Sari ◽  
Agus Alex Yanuar ◽  
Meldi Rendra
Keyword(s):  
Injection Molding ◽  
Waiting Time ◽  
Preventive Maintenance ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Future State ◽  
Fishbone Diagram

CV. Gradient merupakan perusahaan manufaktur yang memproduksi plastik menggunakan mesin injection molding. Produk pada penelitian ini fokus pada produk spring guide dengan tipe XXX. Berdasarkan hasil observasi, wawancara dan kuesioner terdapat beberapa waste yang ditemukan dalam proses produksinya, salah satunya adalah waste yang menjadi fokus penelitian yaitu waste waiting time. Metode untuk meminimasi waste tersebut adalah dengan menggunakan konsep lean manufacturing. Penelitian dimulai dengan melakukan observasi dan wawancara untuk memperoleh data-data yang menunjang pemetaan proses produksi spring guide yang terjadi dengan menggunakan value stream mapping (VSM) dan process activity mapping (PAM) sehingga diketahui total waktu non-value added akibat waste waiting time adalah 7161.87 detik atau 57.8% dari lead time. Setelah itu, dilakukan analisis akar penyebab waste waiting time dengan menggunakan 5 whys dan fishbone diagram. Hasil dari analisis akar penyebab waste dapat digunakan untuk menentukan usulan rancangan yang akan dibuat berupa jadwal pemeliharaan mesin injection molding menggunakan preventive maintenance untuk mengurangi aktivitas non-value added. Pada kondisi yang akan datang, usulan rancangan dapat menghilangkan waktu menunggu dan waktu perbaikan yang menyebabkan waste waiting time. Berdasarkan future state total waktu non-value added dapat dikurangi menjadi 721.87 detik atau 12.12% dari lead time yang diperoleh dari penghilangan aktivitas menunggu dan aktivitas perbaikan.

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