Metal stamping industry has Quick Die Change (QDC) as a form of Single Minutes Exchange of Dies (SMED) as an efficient production technique where the implementation depends on operator’s activities, clamping system, accessories type and position, etc. This QDC could apply to improve the process efficiency, control of inventory and reducing the cost. This research compared the traditional metal stamping process and QDC System (QDCS) of metal stamping. This research was using Focused Group Discussion (FGD), direct observation and experiments, conducted in a private metal stamping company in wider Jakarta region of Indonesia. It was observed that the QDCS significantly reduces setup time, storage space and the cost. The setup time and cost reduced to one third of the conventional and the requirement of storage decreased by 70%. In addition, QDCS reduces the waste significantly.

This research was performed on 3 cutting tools which are tool drill 1.8mm, 2.5mm in diameter and tool back chamfer 2.2mm in diameter. Hardness value from each cutting tool was approximately 300 HRC. Meanwhile, material used in this research is SUS 420 that has hardness value 262HRC. To perform cutting on work unit, it was requested higher hardness value for cutting tool compared to work unit (SUS420). Tool drill 1.8mm in diameter was used at first pitting process (rapping), tool drill 2.5mm in diameter was used at second pitting process (finishing) and tool back chamfer 2.2mm in diameter was used at the last pitting process. This research was performed to define the tool life of cutting tools that utilized in milling machine from work unit material SUS 420. From this research, it was expected maximum amount that can be achieved from cutting tools every replacement can be obtained. At the end of study, when the replacement time of cutting tools can be defined, the loss of not good product (because of cutting) can be avoided. Based on the result, tool life of cutting tool was 920 cuttings.

The rapid developing of technology today has forced manufacturing companies to widely expands their business and production abilities. Efficiencies in all aspects must be taken to maximized production capacity and reduce waste to survive. Lean’s SMED technique is one of waste reduction method that usually used in manufacturing companies and specifically called the Quick Die Change (QDC) for metal stamping companies. But some research related to QDC only discuss the setup tools and operator movement during setup and process. This research observed the setup process of the die construction that has been modified to be able to reduce the setup time and other time wasted activities. This QDC die construction could save setup time by 60% compared to conventional die and could do more if carefully planned. Research conducted in an automotive spare parts maker in Jakarta wider region that already use this QDC die in their production line.

This research was conducted at PT. HDD, which is a Japanese PMA and is engaged in manufacturing HDD (Hard Disk Drive) components. On mid of August 2020, customer of PT. HDD revise the order quantity. Customer reduce order quantity from August to December 2020.With the phenomenon of decreasing orders, it is necessary to make efforts to reduce production costs. By reducing production costs, it is expected that the company will get profit. Reduction of production costs is carried out on labor costs and utility costs (water and electricity). To achieve this goal, management established 5 policies so that labor costs and utility costs (electricity and water) were reduced.The policies taken relate to eliminating / controlling overtime hours, stop contract employees and not recruit new employees, moving employees from the excess employee section to the understaffed section, reducing days work for 3 days (done in September 2020) and reduce work days by 2 days (done in October 2020).

The research was conducted to increase the productivity of the sandblasting machine on the SSIP model at PT. XYZ. The average productivity in March 2017 was 238 pieces / hour, which is below the productivity target set at 400 pieces / hour. Refer to root cause analysis low productivity on the sandblasting machine due to machine settings. The sandblasting machine settings before being changed were turn table parameters 15Hz , rotary gun parameters 50 Hz and pressure parameters 5 bar. By conducting several experiments on parameter combinations, parameter combinations can be obtained that can reduce cycle time and do not affect to product quality. The new sandblasting machine settings are 17 Hz turn table parameters, 60 Hz rotary gun parameters and 6 bar pressure parameters. The cycle time for setting up the new sandblasting machine is 9 seconds, equivalent to a productivity of 400 pieces / hour. So that productivity increases by 68% (from 238 pieces / hour to 400 pieces / hour).