MY FINAL PROJECT
"APPLICATION LEAN MANUFACTURING
IN THE PRODUCTION PROCESS SPUN PILE USING WASTE ASSESMENT MODEL (WAM) AND VALUE
STREAM ANALYSTS TOOLS (VALSAT)"
Siti Nurlina1, Syarif
Hidayat1
1Industrial Engineering Department, Faculty
of Science and Technology
Al Azhar University Of Indonesia,
Sisingamangaraja Street, Jakarta 12110
E-mail : nurlinasiti17@ymail.com
Abstract
- Lean manufacturing is a concept that can help
companies become more efficient and effective especially in terms reducing
of waste. Waste that occurs can Causing
non efficiency and influence operating cost of company. In this research Writer
identifing waste the production process spun pile PT. Adhimix Precat Indonesia
by using Waste Relationship Matrix (WRM), Waste Assessment Questionnaire (WAQ)
, Value of Stream Mapping Tools (VALSAT) and Takt Time. The results of this
research showing dominant wastes that occur during the production process spun
pile are waste of process, transportation and motion with the percentage of
each is 28,35 % , 14,12 %, and 13,06 % and based on one of tools value steam
mapping that is process activity mapping the application of lean manufacturing
process Cycle Efficiency the factory increase as much as 12 % from 70 % to 82 %
and lowering the activity of non value added as much as 10% of 11% to 1%.
Kata
Kunci : Lean Manufacturing, Waste, Value Stream Mapping
Tools
1. INTRODUCTION
1.1 Background
Of Problem
As providers of concrete products with
the amount of a high order PT. Adhimix Precast Indonesia must have a strategy
of sustainable and development of intensive plan so that all the needs of
consumers and market demand could fulfilled and innovation in strengthen
internal management of PT. Adhimix Precast Indonesia to accomplish a purpose maximum
profit can be achieved.
Difficulty in
achieving a daily production
target as
much as 7% of the initial
plan had been planned
by PT. Adhimix Precast
Indonesia due to some
activity waste that
does not give add value to the production process as unnecessary movement, long lead time, inter location that
so far and waiting. One of the effective and efficient
management strategies that can be applied
to reduce the
wastage rate is
the concept of lean
manufacturing.
1.2 Restriction Of Problem
Restrictions problem in this research are:
1.
Research
focused on the process of producing a kind spun pile by PT.Adhimix Precast
Indonesia
2.
Historical
data used in this research is data production process of Januari – September
2014
3.
Data
required in this study focused on the time of the production process and not
discuss about cost
4.
The study is limited to the stage of recommendations for improvements to the
level of dominant waste.
1.3 Formulation Of Problem
1.
What
Type of Waste is
the most dominant in the production process Spun pile by PT. Adhimix Precast Indonesia ?
2.
What activities are non-value added activities
in the production of spun pile PT.
Adhimix Precast Indonesia ?
3. How much
different value of process cycle efficiency in
the production process Spun Pile before
and after application of the concept lean manufacturing ?
1.4 Purpose Of Research
1.
Determine and quantify the most
dominant type of waste
in the production process Spun pile.
2.
Identifying and measuring the activity of non-value added in the production process Spun Pile.
3.
Calculate and compare the value of procces cycle ffficiency Spun
Pile before and
after application the concept of lean
manufacturing.
2.
LITERATURE
2.1 Lean Manufacturing
Lean
manufacturing is a systemic and systematic
approach to identifying
and eliminating waste (waste) which includes
non value-added activities through continuous
improvement.
2.2 Waste
There are
seven types of waste are
identified by Shigeo
Shingo consists of (Hine and Taylor, 2000) Consists of
:
1.
Overproduction
2.
Defect or Reject
3.
Unnecessary Inventory
4.
Inappropriate Processing
5.
Excessive Transportation
6.
Waiting atau Idle
7.
Unnecessary Motion
2.3 Value Stream Mapping
VSM is a process of visually mapping the flow of information
and material aimed
at preparing method and a better performance in the future state
map. (Jones and
Womack, 2000)
2.4 Value Stream Analysis Tools (VALSAT)
VALSAT is a tool to map in
detail the value stream, which focuses
on value adding process
so it can be used
to find the cause
of the waste that is happening
(Hines and Rich,
2008). There are seven
kinds of detailed mapping tools most commonly used are:
1. Procces
Activity Mapping (PAM)
2. Supply
Chain Response Matrix
3. Production
Variety Funnel
(PVF)
4. Quality
Filter Mapping
5. Demand
Amplification Mapping (DAM)
6. Decision
Point Analysis
(DPA)
7. Physical
Structure (PS)
Table 2.1 below shows the
correlation and usability
of each value
stream mapping tools for each type of waste.
Tabel 2.1 Value Stream Mapping Tools
Note:
H→ (High Correlation and Usefulness) multiplier = 9
M→ (Medium Correlation and Usefulness) multiplier = 3
L → (Low Correlation and Usefulness) multiplier = 1
H→ (High Correlation and Usefulness) multiplier = 9
M→ (Medium Correlation and Usefulness) multiplier = 3
L → (Low Correlation and Usefulness) multiplier = 1
2.5 Concept of Waste Assessment Models
This model depicts the relationship between the seven waste
is overproduction (O), processing (P),
inventory (I), transportation
(T), defect (D),
waiting (W), and
motion (M).
2.6
Waste
Relationship Matrix (WRM)
WRM is a matrix that is
used to analyze the criteria
of measurement. Line on waste indicates the effect of each waste with other waste sixth.
While the matrix
column shows the
waste that is influenced by
other waste.
Tabel 2.2 Matrix WRM
After the degree of strength relationship between waste identified
the letters from the table WRM converted
into a value with
a score of A =
10, E = 8, I = 6, O = 4, N = 2, and X = 0. Table 2.3 below is ilustarsi
of waste value
relationship value.
Tabel 2.3 Waste Matrix Value
2.7 Waste
Assesment Questionnaire (WAQ)
WAQ made to identify and allocate
waste that occurs on the production line
(Rawbdeh, 2005). Assessment
Questionnaire consisting of 68 questions that represent the activity, condition or behavior
in specific production
floor can generate
waste. Any questions
on the assessment questionnaire consists of
three pieces each
answer with a
weight of 1, 0.5 and 0. The question was categorized
into four groups: man, machine, material
and method. Ranked
end of waste
depends on the
combination of answers.
3.
METHOD
OF RESEARCH
Figure 3.1 shows research stage from the beginning until the end of this
research was. This research begin by determining research topic, making
formulation of the problem, research objective, distributing questionnaire,
data processing and result, for the detail stage can be seen in the Figure 3.1
Figure 3.1 Stages of Research
