Pendekatan Lean Manufacturing untuk Mereduksi Waste Menggunakan Metode Value Stream Mapping dan FMEA pada Produk Kusen di UD. Herman Jaya

Abstract

UD. Herman Jaya is a manufacturing company engaged in the furniture industry. The company faces challenges in the form of waste, namely significant time wastage between the actual time observed and the standard time set by the company, as well as a scrap rate exceeding the company's standard of 5%, resulting in the failure to achieve production targets. The objective of this study is to reduce waste through a Lean Manufacturing approach using the Value Stream Mapping method and to propose improvements using the Failure Mode Effect Analysis (FMEA) method. Based on observations and measurements at UD. Herman Jaya, there are 20 activities with non-value-added time of 2,117.68 seconds, manufacturing lead time of 3,228.61 seconds, process cycle efficiency of 65.59%, and process velocity of 22.32 processes per hour. Subsequently, three non-value-added activities and one necessary non-value-added activity were eliminated, resulting in improvements with a reduction in activities to 16, non-value-added time to 0.00 seconds, manufacturing lead time to 2,335.22 seconds, process cycle efficiency increasing to 90.68%, and process velocity to 24.67 processes/hour. Following the improvements, there was an increase in monthly production from 260 units/month to 331 units/month. Based on the analysis using FMEA, the RPN values for each waste were as follows: waste overprocessing in measuring the length of cut wood, with the root causes being the method (315) and the machine (288); waste overprocessing in re-flattening the wood surface using a planer machine, with the root causes being the material (392) and the machine (336); and waste waiting due to wood accumulation on the trolley, with the root causes being the method (384 and 336). The proposed improvements include replacing the automatic crosscut saw machine and establishing its operating procedures, conducting strict wood selection inspections and providing storage racks, as well as implementing a regular maintenance schedule for the saw blades, and arranging the assembly station layout to be adjacent to the sponning station and establishing delivery standards to the assembly station in a single batch