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All Journal Journal of Artificial Intelligence and Digital Business Jurnal Ragam Pengabdian
Rahmadiyani, Rani
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Computer Science & IT Economics, Econometrics & Finance Electrical & Electronics Engineering Engineering Environmental Science Social Sciences Other

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Integration of VSM and SMED for Optimization of the CCB Milling Process Yusrizal; Darmawan, Heru; Rahmadiyani, Rani
Jurnal Ragam Pengabdian Vol. 3 No. 1 (Spesial Issue) (2026): "Dharma Samudera"
Publisher : Lembaga Teewan Journal Solutions

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.62710/v3ny6d36

Abstract

Productivity improvement in manufacturing systems requires systematic identification and elimination of waste, particularly in bottleneck processes. This study was conducted at PT XYZ, an automotive component manufacturer experiencing low productivity in the CCB part production line. The milling process was identified as the primary bottleneck, with an initial cycle time of 472 seconds for 6 pieces and an average output of 550 pcs/day, achieving only 75.6% of the production target. This research aims to identify the causes of waste, reduce cycle time in the milling process, and increase production output in line with management targets. The study applies Value Stream Mapping (VSM) to analyze material and information flow, Process Activity Mapping (PAM) to classify internal and external activities, and the Single Minute Exchange of Dies (SMED) method to minimize setup time. Improvements were implemented using the PDCA (Plan–Do–Check–Act) cycle. Root cause analysis using fishbone and 5W+1H identified manual clamping operations as the main contributor to excessive internal time and variability. A semi-automatic pneumatic clamping system was introduced to replace manual bolt tightening and clamp handling. The results show a reduction in internal setup activities from 12 to 9 activities and a decrease in cycle time from 472 seconds to 425 seconds (9.9%). Consequently, daily production output increased from 550 pcs/day to 652 pcs/day, representing an 18.5% productivity improvement and exceeding the initial 10% target. The findings confirm that integrating VSM and SMED with semi-automation effectively enhances operational performance without full-scale automation investment.
Analisis Akar Penyebab dan Usulan Perbaikan Cacat Scratch Pada Produk Exhaust Gas Recirculation (EGR) dengan Pendekatan Six Sigma DMAIC Fadill, Akhmad; Intani, Arvita Emarilis; Rahmadiyani, Rani
RIGGS: Journal of Artificial Intelligence and Digital Business Vol. 5 No. 1 (2026): Februari - April
Publisher : Prodi Bisnis Digital Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/riggs.v5i1.8391

Abstract

Penelitian ini bertujuan untuk menurunkan tingkat cacat scratch pada produk Exhaust Gas Recirculation (EGR) di PT Aisan Nasmoco Industri menggunakan metodologi Six Sigma DMAIC. Berdasarkan data periode Juli–September 2025, kapabilitas proses saat ini berada pada level 3,64 Sigma dengan nilai DPMO sebesar 16.200, yang menunjukkan bahwa proses masih belum berada pada kondisi optimal. Hasil analisis pada tahap Define, Measure, dan Analyze mengidentifikasi bahwa akar penyebab utama cacat berasal dari kondisi teknis jig besi dan klem tuas yang tajam tanpa pelapis pelindung, serta rendahnya tingkat kepatuhan operator terhadap SOP penanganan material. Selain itu, ditemukan pula bahwa sistem pengawasan yang belum konsisten turut memperbesar potensi terjadinya cacat selama proses produksi berlangsung. Usulan perbaikan difokuskan pada modifikasi jig dengan penambahan pelapis karet (urethane) untuk mengurangi kontak langsung antar logam, serta pengetatan pengawasan terhadap standar penumpukan dan pemindahan produk. Perusahaan juga disarankan untuk meningkatkan efektivitas pelatihan operator secara berkala dan menerapkan kontrol visual sebagai pengingat prosedur kerja yang benar. Implementasi perbaikan ini diharapkan mampu mengurangi variasi proses, meningkatkan kapabilitas produksi, serta menurunkan nilai DPMO secara signifikan. Tahap Control dilakukan melalui monitoring berkala dan standarisasi prosedur guna memastikan keberlanjutan hasil perbaikan. Dengan pendekatan ini, perusahaan diharapkan dapat meningkatkan kualitas produk, efisiensi operasional, serta kepuasan pelanggan secara berkelanjutan dan memperkuat daya saing perusahaan di industri.
Co-Authors Darmawan, Heru Fadill, Akhmad Intani, Arvita Emarilis Yusrizal