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 Variability and Uncertainty Analysis in Value Stream Mapping

2019 ◽  
Vol 8 (12S2) ◽  
pp. 533-538
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Strong Impact ◽  
Food Sector ◽  
Value Stream ◽  
Current State ◽  
Potential Risks ◽  
Tools And Techniques ◽  
A Current

Lately, value stream mapping (VSM) is integrated with tools and techniques that belong to other areas of knowledge such as risk management (RM). It is well known tool in showing the value, value stream and the flow which represents three of lean manufacturing (LM) principles. This integration, gives more benefit in covering two of VSM issues such as considering the variability and uncertainty of production processes. In this paper, a model named variable value stream mapping (V-VSM) that integrates the two was showed, explained and tested. The model helps to generate the VSM in a dynamic way with the identification of current and potential risks. These risks might happen in the future bringing a strong impact on not reaching the main objectives in the defined time and cost. The model has been tested by conducting a case study in food sector. A current state map was built using both models, traditional VSM and VVSM. The results showed the effect of variability and uncertainty on the total cycle time (CT) and lead time (LT) values, where the traditional VSM failed to show it by being a static tool. Comparing the results of both models show the differences in presenting the real state of manufacturing environment..

scholarly journals Production flow improvement and value stream mapping in a lean manufacturing world

2021 ◽  
Vol 6 (1) ◽  
pp. 036-050
Author(s):  
Muhammad Adib Uz Zaman ◽  
Emad Rabiei Hosseinabad
Keyword(s):  
Lean Manufacturing ◽  
Performance Metrics ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Assembly Simulation ◽  
Kaizen Events ◽  
Load Leveling ◽  
And Performance ◽  
Flow Improvement

The importance of lean manufacturing concepts has been discussed many times over the few decades. The most important elements in lean manufacturing practices are value stream mapping (VSM), Kaizen events, load leveling (heijunka), etc. In this case study, a real-world clock assembly simulation has been used to study the performance improvement in terms of production flow and lead time after introducing lean concepts. In each round of simulation, the lean concepts have been introduced one by one and performance metrics were recorded. After implementing the concepts, the productivity was improved enormously. So, this simulation study emphasizes the importance of continuous improvement of production flow through lean concepts in a real production setting.

scholarly journals ANALISIS PEMBOROSAN PRODUKSI PADA ALIRAN PRODUK JALA IKAN KKP MENGGUNAKAN PRINSIP LEAN MANUFACTURING DENGAN METODE VALUE STREAM MAPPING (VSM) DI PT. INDONEPTUNE NET MANUFACTURING

2019 ◽  
Vol 7 (2) ◽  
pp. 79-89
Author(s):  
Henny Henny ◽  
Muhammad Kahfi Hadi Syuhada
Keyword(s):  
Cycle Time ◽  
Delay Time ◽  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Time Level ◽  
Value Stream ◽  
Current State

  Penelitian ini ditujukan untuk menganalisis pemborosan produksi produk Jala Ikan KKP menggunakan lean manufacturing di PT. Indoneptune Net Manufacturing dengan memetakan aliran produksi dan menganalisisnya menggunakan value stream mapping (VSM). Analisis terhadap pemborosan dengan metode VSM dilakukan karena VSM dapat memetakan aliran informasi dan material dari awal sampai akhir dari value stream pembuatan suatu produk. Sehingga dapat dilihat proses mana saja yang merupakan pemborosan. Adapun VSM yang dibuat adalah current-state VSM karena dapat merepresentasikan kondisi saat ini dari aliran produksi yang ada. Hasil yang didapatkan setelah dibuat current-state VSM adalah aliran produksi produk jala Ikan KKP melewati proses spinning, ring roupe, netting dan finishing yang memiliki sub-sub proses yang berbeda. Dari setiap sub-proses tersebut dipetakan nama proses, jumlah waktu cycle time dan changeover time, level inventory, waktu kerja tersedia dan jumlah operator. Penganalisisan pemborosan dilakukan pada setiap sub-proses untuk dapat mengetahui nilai tambah proses tersebut terhadap produk utama yang sedang dikerjakan pada setiap tahapan proses yang berlangsung. Kesimpulan yang didapat yaitu pemborosan yang terjadi di departemen spinning salah satunya adalah delay time karena persiapan sebelum proses peleburan, waktu tunggu karena persiapan proses twist di departemen ring roupe, transportasi berlebih sebelum proses tatekan dan pengerjaan ulang di hoshu 2 di departemen finishing.

scholarly journals Energy Analysis via Value Stream Mapping: A case study of an Automotive Weld Plant

ORiON ◽  
2021 ◽  
Vol 37 (2) ◽  
Author(s):  
Keshav Ramsunder ◽  
Oludolapo Olanrewaju
Keyword(s):  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Measuring Instruments ◽  
Manufacturing Companies ◽  
Step Method ◽  
Empirical Observation ◽  
Value Stream ◽  
Starting Point

Over the past few decades, Lean Manufacturing (LM) has been the pinnacle of strategies applied for cost and waste reduction. However as the search for competitive advantage and production growth continues, there is a growing consciousness towards environmental preservation. With this consideration in mind this research investigates and applies Value Stream Mapping (VSM) techniques to aid in reducing environmental impacts of manufacturing companies. The research is based on empirical observation within the Chassis weld plant of Company X. The observation focuses on the weld operations and utilizes the cross member line of Auxiliary Cross as a point of study. Using various measuring instruments to capture the emissions emitted by the weld and service equipment, data is collected. The data is thereafter visualised via an Environmental Value Stream Map (EVSM) using a 7-step method. It was found that the total lead-time to build an Auxiliary Cross equates to 16.70 minutes and during this process is emitted. It was additionally found that the UPR x LWR stage of the process indicated both the highest cycle time and carbon emissions emitted and provides a starting point for investigation on emission reduction activity. The EVSM aids in the development of a method that allows quick and comprehensive analysis of energy and material flows. The results of this research are important to practitioners and academics as it provides an extension and further capability of Lean Manufacturing tools. Additionally, the EVSM provides a gateway into realising environmental benefits and sustainable manufacturing through Lean Manufacturing.

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.

Development of Computerize Value Stream System

2014 ◽  
Vol 915-916 ◽  
pp. 1405-1411
Author(s):  
A.N.A. Ahmad ◽  
Sulaiman Hj. Hasan ◽  
H. Norafifah
Keyword(s):  
Lean Manufacturing ◽  
Mapping Method ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Traditional Concept ◽  
Value Stream ◽  
Stream System ◽  
Manufacturing Company ◽  
Value Streams ◽  
Individual Value

Value stream mapping (VSM) was initially developed to use of the suite of tools to help researcher or practitioner to identify waste in individual value streams and find an appropriate method to its removal. The process itself is simple and straightforward is used to identify waste using lean manufacturing technique, determined causes of the waste through the value stream mapping method and to propose solution to improve workplace environment. In this project is made an attempt to computerize the process though the application of VSM. Computerize value stream system is basically a method which is an internet networking system combining traditional concept of value stream mapping method to be used at manufacturing company to reduce wastes. This paper summarizes the way to develop an internet, online and network based of an efficient computerize value stream system to improve operation value of the manufacturing company. This paper reviews the design of package that will replace the manual method of doing VSM. This package will be applied in a real shop floor environment.

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