Implementation of Lean Manufacturing To Reduce Waste in Calliper Bracket Production
DOI:
https://doi.org/10.33021/jie.v10i01.60Keywords:
lean manufacture, waste, lead time, output, VSM, PAM, 5S methodologyAbstract
Initial observations at PT. PPE showed that the production of calliper brackets failed to meet monthly targets for four consecutive months. Investigations carried out by the team showed that the inability to meet production targets was caused by waiting and transportation activity, which can cause longer production lead times. Some wastes were found, such as waiting for a forklift, and transportation of material movings between workstations. To overcome this problem, PT. PPE uses 5S, one of the lean manufacturing tools. The research began with direct observation to determine the actual production floor situation. The next stage is the problem identification process using Value Stream Mapping (VSM), Process Activity Mapping (PAM), spaghetti diagram, and fishbone diagram. Some 5S-based corrective actions implemented include sorting unused goods, arranging materials, maintaining cleanliness, updating work instructions, and creating a 5S check sheet. The result of implementing 5S in calliper bracket production was that lead time decreased from 8.05 days to 5.53 days or 31.30%. Sales losses can be reduced from IDR 1,936,100,000 to IDR 111,150,000 or decrease by 94.26%.
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