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All Journal International Journal of Mechanical Engineering Technologies and Applications (MECHTA)
Adiprasetyo, Farras
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Automotive Engineering Energy Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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Optimization of the Production Process of Forging Dies for Piston Wheel Cylinders using Value Stream Mapping and the 7 Wastes Method Marizka, Dewi Auditiya; Adiprasetyo, Farras; Rozzan , Falahi; Gibran , Jubair Azhar Rahman; Suwanto , Febrian Adiputra; Pratama, Adji Ningrat Isma
International Journal of Mechanical Engineering Technologies and Applications Vol. 7 No. 2 (2026): July - December 2026
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2026.007.02.9

Abstract

Improving production efficiency is an important challenge in the manufacturing industry, particularly in automotive component production. This study analyzes the production process of Dies Forging Piston Wheel Cylinder (DFPWC) using Value Stream Mapping (VSM), 7 Wastes analysis, Fishbone Diagram, 5W+1H analysis, and Failure Mode and Effects Analysis (FMEA). The analysis was conducted to identify non-value-added activities, determine the root causes of production delays, and develop improvement strategies. The current-state VSM showed a total production time of 6,478 minutes, with 5,028 minutes identified as non-value-added time. The main problems included waiting caused by unavailable jigs, operators performing multiple tasks, inadequate machine maintenance, and insufficient control of supporting materials. Based on the identified causes and FMEA results, a future-state VSM was developed. The proposed improvements reduced the total production time to 6,270 minutes and non-value-added time to 4,820 minutes. These results indicate that the integration of VSM with waste and root-cause analysis can support the development of improvement strategies for reducing production delays and improving process efficiency.
Co-Authors Dewi Auditiya Marizka Gibran , Jubair Azhar Rahman Pratama, Adji Ningrat Isma Rozzan , Falahi Suwanto , Febrian Adiputra