Lean Assessment Matrix: A Proposed Supporting Tool for Lean Manufacturing Implementation

Abstract

During lean manufacturing implementation, some supported tools are required. Value Stream Mapping, Process Activity Mapping, Root Cause Diagram, Failure Mode Effect Analysis, Pareto chart are some examples of the tools that has been widely utilized. However, a tool that is able to support lean manufacturing implementation starting from waste identification until suggest improvement for eliminating waste, is very few. This research proposes a tool that could assist company comprehensively when applying lean manufacturing. The tools, which is called Lean Assessment Matrix, consists of two matrix but it could cover the complete stages of lean implementation starting from waste and their causes identification, the critical waste prioritizing as well as provides waste reduction plan alternatives and their ranks. Lean Assessment Matrix is developed by modifying House of Risk Matrix and integrates with combining Waste Relationship Matrix. Lean Assessment Matrix is being develop with the same approach as of HOR. This tool consist of two matrix which are lean matrix 1 and lean matrix 2. Lean matrix 1 are used to identify waste and its root causes, and determining the rank of waste by considering waste relationships. Lean matrix 2 is aimed to provide alternative actions to reduce or eliminate root causes of selected waste from matrix 1 as well as their priority level.

Lean Manufacturing Approach to Improve Speaker Manufacturing Process

“…The mapping result of Lean Matrix 1 can be seen in Table 8. The calculation step is following [4]. The result of Lean Matrix 1 are priority rank of waste (transportation, waiting, and motion) that need to be analyzed more in Lean Matrix 2.…”

“…The mapping result of Lean Matrix 2 can be seen in Table 11. The calculation step is following [4]. The result of Lean Matrix 2 are rank of action priority of waste elimination.…”

“…There is no PWB destination marking standard activity mapping. The lean manufacturing approach used for waste elimination is carried out with the Lean Assessment Matrix (LAM) developed by [4]. This method is a modification and integration of the House of Risk (HOR) and Waste Relationship Matrix (WRM) that can comprehensively fulfill all stages of lean manufacturing implementation from waste and root causes of waste, determination of critical waste, alternative actions to eliminate root causes of waste and its priorities.…”

Development of Monitoring Tool to Support Lean Manufacturing Implementation

“…In 2019, P. D. Karningsih, A. T. Pangesti, and M. Suef developed a Lean Assessment Matrix (LAM) tool. The development of the Lean Assessment Matrix (LAM) follows the same logic as the House of Risk (HOR) [10]. Some modifications were applied to fit lean implementation goals.…”

“…The Lean Monitoring Tool developed in this research is the next step in the implementation stage of lean manufacturing [9]. This tool will be an advanced tool of the Lean Assessment Matrix (LAM) developed by P. D. Karningsih, A. T. Pangesti, and M. Suef, where the LAM serves to identify waste and the root causes of waste to obtain recommended steps to eliminate effective waste [10]. After getting a recommendation for corrective action or waste elimination…”