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All Journal Spektrum Industri
Diyah Dwi Nugraheni
Department of Textile Engineering, Universitas Islam Indonesia, Yogyakarta 55584, Indonesia
Decision Sciences, Operations Research & Management Engineering Environmental Science Industrial & Manufacturing Engineering Materials Science & Nanotechnology

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Improving Production Efficiency of NC-212 Aircraft Outer Wing Assembly Using Value Stream Mapping and Kaizen Approach Dwi Adi Purnama; Diyah Dwi Nugraheni
Spektrum Industri Vol. 24 No. 2 (2026): Spektrum Industri - October 2026
Publisher : Universitas Ahmad Dahlan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.12928/si.v24i2.606

Abstract

Manual aircraft wing assembly is characterized by long lead times, process variability, and waste that reduce production efficiency. This study aims to improve the NC-212 Outer Wing Left-Hand (LH) assembly process by applying lean manufacturing through Value Stream Mapping (VSM), root-cause analysis, and Kaizen-based improvements. Primary data were collected through direct observations, time studies, and interviews across 12 assembly stations. The current-state analysis identified waiting due to pending parts, unnecessary transportation, defects, and manpower imbalance as the dominant sources of waste. Based on Five-Whys and 5W+1H analyses, improvement strategies and takt-time-based workforce allocation were developed to optimize production flow. The proposed future state reduced assembly lead time from 75 to 59 working days (21.3%) and increased average labor utilization to 96.16% through workload balancing and reduced idle time. The main contribution of this study is the application of VSM-based lean improvement integrated with takt-time-based manpower scheduling for a high-mix, low-volume aerospace assembly environment. The proposed framework provides practical guidance for improving workflow synchronization and supporting continuous improvement in aircraft manufacturing systems.
Co-Authors Dwi Adi Purnama