ISSN No:-2456-2165
Abstract:- In general the purpose of a manufacturing Ineffective and efficient production processes can lead to
industry is to produce economical goods in order to obtain non-current production, such as the accumulation of raw
profits and be able to meet customer needs on time. With materials and semi-finished goods (WIP) on the production
the increase in sales projections and significant customer floor called bottlenecks. Bottlenecks can be caused by an
demand, an analysis needs to be made regarding the imbalance in the time of each process on the production floor
company's ability to carry out the production process. where there is a process that takes a very long time. The
Therefore, one of the determining factors in order to be reason is because the management system in managing
able to compete in the industrial world today is to resources is less efficient. For that factors that influence in
implement lean production, namely through an operating each process must always be evaluated whether it can still be
management system approach by eliminating operational said to be relevant to the conditions of the business being run
processes that are not needed to achieve effective and or need to be improved (kodradidkk, 2008).
efficient productivity. Ineffective and efficient production
processes can cause production to be hampered such as the From the application of lean production can be expected
accumulation of raw materials and intermediate goods to reduce production costs, increase the output produced, and
(WIP) on the production floor. The application of lean lead to shorter production time (Hawien, 2008). In the concept
production is expected to be able to reduce production of lean production activities are divided into activities that are
costs, increase output produced, and production lead time value added, not value added and activities that are important
to be shorter. but do not add value to production (Hines&Rich, 1997).
Transportation Time
Value Stream Mapping (VSM) Count the time of each process
Inventory
VSM is a tool from lean manufacturing that originally came
from the Toyota production system (TPS) known as "material Identify waste that occurs in
and information flow mapping" (WPI, 2007). Russell and the company
Shook (1999) define the concept of VSM as a powerful tool
that can not only define processes but also can be a guide in
making improvements. Even farther. Jones and Womack
Connecting data to find the
(2000) state that the VSM concept is a process of visually relationship between waste
mapping the flow of information and material that aims to
prepare better methods and performance in a future state map
proposal. From this tool, information about the flow of Weighting the results of the
information and physical in the system can be obtained. questionnaire to find out the
relationship between waste
60 To Defact 6 4 10 6 8 6 6
61 From Process 4 3 6 10 0 10 8
62 To Transportation 6 2 2 0 10 0 0
63 From Motion 0 4 6 10 0 6 4
64 From Motion 0 4 6 10 0 6 4
65 From Motion 0 4 6 10 0 6 4
66 From Overproduction 10 44 6 6 6 0 2
67 From Process 4 3 6 10 0 10 8
68 From Defact 2 2 10 6 2 0 6
Total Score 236 254 430 416 232 278 338
Table 4:- Initial Weight obtained from WRM
Calculate the final value of waste factor (yj Final) by entering the influence probability factor between the type of waste (Pj)
based on the total "From" and "To" on WRM by multiplying the percentage.
O I D M T P W
WASTE RATING
30
20.39 21.33
20 14.67
11.92 10.6 10.95 10.15
10
0
O I D M T P W
Mapping Tool
Supply Demand Decisi
Process Produc Quality Physical
Waste Weight Chanin aplicati on
aktivity tion filter struture
respon on plant
mappin variety mappin mappin
se mappin analysi
g finnel g g
matrix g s
Overprouctio
11.92 11,92 35,75 0 11,92 35,75 35,75 0
n
Unnecessary
10.60 31,8 95,39 31,8 0 95,39 31,8 10,6
Inventory
Defact 20.36 20,39 0 0 183,54 0 0 0
Unnecessary
21.33 191,93 21,33 0 0 0 0 0
motion
Transportatio
10.95 98,51 0 0 0 0 0 10,95
n
Inapproproate
10.15 91,35 0 30,45 10,15 0 10,15 0
processing
Waiting 14.67 132,03 132,03 14,67 0 44,01 44,01 0
Total 577,93 284,5 76,92 205,61 175,15 121,71 21,55
Peringkat 1 2 6 3 4 5 7
Table 6:- Results of the Mapping Tool
Based on the calculation of the results of the VALSAT tools mapping above, the results and rankings can be described in the
graph below
577.93
600
500
400
284.5
300 205.61
175.15
200 121.71
76.92
100 21.55
0
PAM SCRM PVF QFM DAM DPA PSM
Days Physical stock Cummalative Days Physical Stock Lead Time Cummulative Lead Time
Total 3.714
Tabel 7:- Days Physical Stockdan Lead Time
500
state 2
400
300 state 3
200
100
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Fig 5:- Production Results Before and After Repair
V. CONCLUSION
REFERENCES
A design for the Lean Production System was obtained,
with better production process performance by eliminating [1]. Gahan, Sean M. (2007), “Adding Value To Value Stream
waste from identification results with analysis. The design can Mapping: A Simulation Model Template For VSM”,
be seen in the Future State Value Stream Mapping. Proceedings of the 2007 Industrial Engineering Research
Conference.
Based on the results of identification of waste by using [2]. Gasersz. Vincent, (2007). Lean Six Sigma For
the Waste Assessment Model (WAM) method which consists Manufacturing And Service Industries, PT Gramedia
of the Waste Relationship Matrix (WRM) and Waste Pustaka Utama Jakarta.
Assessment Questionnaire (WAQ). It was found that the most [3]. Ibrahim A. Rawabdeh. A Model for Assessment of Waste
influencing the occurrence of other waste is the process of in Job Shop Environment. International Journal of
19% and the most affected waste by other waste is a defect of Operations 7 Production Management Vol.25 No.8 2005
21.3%. Then for the final result of Motion in the first rank of [4]. Rother, M., & shook, j. 1999 Learning to See: Value
21.33%, Defect is 20.30%. and Waiting with a weight of Stream Mapping To Create Value And Eliminate Muda.
14.67%. Lean Enterprise Institute. Cambridge. MA.
[5]. Tilak, Minakshi, Elieen Van Aken, Tom McDonald. And
Using the VALSAT method in selecting detailed Kannan Ravi. “Value Stream Mapping: A Review and
mapping tools, the top three priority tools are as follows: Comparative Analysis of Recent Applications”.
Process Activity Mapping (PAM) with a score of 577.93.
Supply Chain Response Matrix (SCRM) with a score of
284.50.
Quality Filter Mapping (QFM) with a score of 205.60.