Implementation of lean manufacturing to reduce waste in production line with value stream mapping approach and Kaizen in division sanding upright piano, case study in: PT. X

Abstract

PT. XY produces musical instruments such as Upright Pianos and Grand Pianos. Due to a competitive competition, a good quality product is highly required as well as increasing the production scale. To achieve these objectives, company needs to reduce wastes occurred in its production lines, particularly in the division of sanding panel upright piano (UP) which produces type of PE B1 pianos. High cycle time and lead-time are caused by wastes in UP panel sanding division. Therefore, it is needed improvements to be applied here so that the production lines will be run more effectively and efficiently. This study aims to identify wastes using Value Stream Mapping (VSM) as a tool of lean manufacturing and to implement the improvements using Kaizen. It is found that the wastes are motion and waiting. Furthermore, the improvements (kaizen) are focused on reducing motion and waiting wastes. It is shown that cycle time decreased from 51.16 minutes to 41.90 minutes, work in process or inventory can be reduced to 24 pcs over 32 pcs, and the lead-time is 0.167 days of 0.222 days.

Waste Identification and Elimination Using Lean Methods in Receiving Process: A Case Study at PT IPC Container Terminal

“…Waste Removal is one of the Important aspects in Lean in which should be focused in Service (Asnan et al, 2015). Waste is any activities that has non-value added (Santosa & Sugarindra, 2018). According to Heizer et al (2017) Waste is any activity that does not add value in the eyes of customer.…”

The Productivity Performance's Measurement in SME Industry by using DMAIC of Six Sigma

“…Current state value stream mapping (VSM) of the aerosol production line was constructed based on observations and data obtained during walks at the production line floor. A tabulation of basic data obtained to facilitate the construction of VSM is illustrated in Tableas follows It was agreeable that VSM enables users to easily identify the different types of time available in the production process and could bring improvements to an organization's production process [7][8] [9][10] [11]. The current state VMS of the aerosol production line produced is shown in Fig.…”

“…Continuous monitoring of process data generated by the aerosol production line during the improvement phase is required as teams seek to achieve optimum solutions implemented to improve the production line, develop and test action plans generated for implementation, controlled planning and validating long term capability of the production line. Kaizen is proven to bring effect of continuous improvement as published in various papers [18] [11].…”

Penerapan Sistem Value Stream Mapping Untuk Peningkatan Hasil Produksi Sparepart Sepeda Motor Mainstand 2sd

“…Hasil penelitian ini sejalan dengan hasil penelitian Lecarda et al (2018) yang menghubungkan relayout dengan efisiensi dari suatu line produksi menggunkan parameter cycle time. Santosa et al (2018) juga menggunakan metode improvement relayout untuk mengurangi waste pada line produksi dengan menggunakan parameter lead time dan cycle time.…”