Lean Approach for Waste Reduction in Production Line by Integrating DMAIC, VSM, and VALSAT Method (Study Case: Assembling Bracket Manufacturing Automotive Industry)
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Published:
Mar 30, 2022
Keywords:
Lean, DMAIC, VSM, VALSAT
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Abstract
The automotive manufacturing industry is a manufacture that produces four-wheeled automotive accessories parts. One of the products is the audio unit and bracket. This research aims to reduce waste in production and reduce cycle time, affecting increasing production output to adapt it to customer needs. Waste identification by integrating lean six sigma, namely DMAIC, VSM, and VALSAT. Based on the analysis results, it was found that the four biggest wastes were motion, inventory, waiting, and process. After carrying out the repair activities, the cycle time decreased at station three from 704 seconds to 246 seconds, thereby increasing the capacity efficiency from 75% to 91 %.
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Kholil, M., Suparno, A., Hasan, S. B. H. ., & Aprilia, R. (2022). Lean Approach for Waste Reduction in Production Line by Integrating DMAIC, VSM, and VALSAT Method (Study Case: Assembling Bracket Manufacturing Automotive Industry). Journal of Intelligent Decision Support System (IDSS), 5(1), 37-43. https://doi.org/10.35335/idss.v5i1.30
References
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Z. L. Dima, “Penggunaan Konsep Lean untuk Meningkatkan Efisiensi Pelayanan Instalasi Farmasi Rawat Jalan di Rumah Sakit Anna Medika Bekasi,” J. Adm. Rumah Sakit Indones., vol. 2, no. 1, 2018.
V. Gasperz and A. Fontana, Lean Six Sigma for Manufacturing and Service Industries. Waste Elimination and Continuous Cost Reduction. Bogor: Vinchristo Publication, 2011.
A. Töpfer and A. Töpfer, Six sigma. Springer Berlin Heidelberg, 2007.
H. Purba, D. Santoso, and J. Haekal, “5S APPLICATION TRAINING ( SEIRI , SEITON , SEIS Ō , SEIKETSU , AND SHITSUKE ) TO IMPROVE THE QUALITY OF WORK ENVIRONMENT IN THE SERVICE INDUSTRY,” no. 2014, pp. 2014–2016, 2016.
A. Syukron and M. Kholil, Six Sigma for Business Improvement. Graha Ilmu, 2013.
J. Shook and M. Rother, Learning to See Value Stream Mapping to Create Value and Elimite Muda. United State of America: he Lean Enteprise, Inc, 2003.
M. Kholil, J. Haekal, and S. Hasan, “Lean Manufacturing Design to Reduce Waste in Gear Production Process Using VSM and Kaizen Method Approaches ( Case Study : Gear Primary Driven K56 Product ),” vol. 7, no. November 2019, pp. 1–9, 2020.
D. Dimancescu, P. Hines, and N. Rich, The Lean Enterprise Designing and Managing Strategic Processes for Customer-Winning Performance. New York: AMACOM, 1997.
D. Caesaron and S. Y. P. S. Simatupang, “Implementasi Pendekatan DMAIC untuk Perbaikan Proses Produksi Pipa PVC (Studi Kasus PT. Rusli Vinilon),” J. Metris, 16 91-96, vol. 16, pp. 91–96, 2015.
R. Hidayat, I. P. Tama, and R. Y. Efranto, “Penerapan Lean Manufacturing Dengan Metode VSM Dan FMEA Untuk Mengurangi Waste Pada Produk Plywood (Studi Kasus Dept. Produksi PT Kutai Timber Indonesia),” J. Univ. Brawijaya, vol. 5, no. 2, pp. 1032–1043, 2014.
A. A. Hidayat, M. Kholil, Hendri, and Suhaeri, “The Implementation of FTA (Fault Tree Analysis) and FMEA (Failure Mode and Effect Analysis) Methods to Improve the Quality of Jumbo Roll Products,” IOP Conf. Ser. Mater. Sci. Eng., vol. 453, no. 1, 2018.