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Journal : OPSI

Production Process Improvement Design to Eliminate Waste in 428H Chain Products Using Lean Manufacturing at PT ABC Sekar Aulia Putri; Amal Witonohadi; Annisa Dewi Akbari
OPSI Vol 15, No 2 (2022): ISSN 1693-2102
Publisher : Jurusan Teknik Industri Fakultas Teknologi Industri UPN "Veteran" Yogyakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31315/opsi.v15i2.7714

Abstract

PT ABC is a manufacturing company that produces several types of chains in large quantities, and one type of chain that is the main focus of this research is the 428H chain. The obstacle faced in producing the 428H Chain is not achieving the production target from June to July, and September to November 2021. The research focuses on minimizing manufacturing lead time using lean manufacturing by eliminating waste in the 428H Chain production process. Waste elimination is done by providing suggestions for improvements based on the identified waste types. The study begins with the calculation of the time sample, then MLT, PCE, the use of the Waste Assessment Model, and mapping current value stream mapping. The initial MLT was 832.95 minutes and PCE was 63.37%. WAM produces the highest percentage of waste in the type of defect, then motion, inventory, waiting, overproduction, motion, and process. The proposed improvements are in the form of designing SOP Operators on Pressing machines, adding Small Incline Belt Conveyor tools, designing SOPs for Activities in the WIP Area, and adding Manual Hand Stacker tools. The provision of improvement proposals resulted in MLT decreasing 12% to 733.2174 minutes and PCE increasing 8.6% to 71.98%, and the production target was achieved with total production per month increasing by 12%, from 21,783 to 24,746 units per month.
The Proposed Warehouse Improvement Using Lean Approach to Eliminate Waste at the Main Warehouse of PT. XYZ Danaswara Amara Dhika; Amal Witonohadi; Annisa Dewi Akbari
OPSI Vol 16, No 1 (2023): ISSN 1693-2102
Publisher : Jurusan Teknik Industri Fakultas Teknologi Industri UPN "Veteran" Yogyakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31315/opsi.v16i1.7310

Abstract

One of the grocery companies in Indonesia provides a multi-channel e-groceries digital platform for online daily shopping activities. One of the important elements that support the operational activities of an e-commerce service industry is the warehouse, which serves as a storage place for goods sold and plays a role in maintaining the quality of products before being sent to consumers. Based on observations and interviews directly with employees at the Main Warehouse, one of the causes of waste in its operational activities is the lack of optimal warehousing activities. This research aims to find out and identify waste in the Main Warehouse’s warehousing activities so that the waste that occurs can be investigated, the implementation of the Lean Warehouse approach is needed in its warehousing activities. The research began with Current State VSM with a PCE value of 47.94%, followed by Process Activity Mapping (PAM) and TIM U WOOD Assessment Questionnaire. The results of this study were obtained based on predictions after the proposed improvements were implemented, there was a reduction in processing time and the amount of waste that occurred in several operational activities at the Main Warehouse. The PCE value increased as 5.22% to 53.16% in the Future State VSM.
Improving sustainability index through the implementation of total productive maintenance for the bending process in electrical manufacturing Shumaesi, Rifdah; Safitri, Dian Mardi; Witonohadi, Amal
OPSI Vol 18 No 1 (2025): OPSI - June 2025
Publisher : Jurusan Teknik Industri, Fakultas Teknologi Industri UPN "Veteran" Yogyakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31315/opsi.v18i1.13176

Abstract

The significant losses caused by breakdowns in the bending machine directly affect Company X. Machines that frequently experience breakdowns can also adversely affect machine efficiency due to the need for component replacements, which contradicts the principle of sustainability aligned with the Sustainable Development Goals (SDGs) aimed at achieving a better and more sustainable future for all. The objective of this study is to improve the sustainability index (SI) through Total Productive Maintenance (TPM) and to calculate the Overall Equipment Effectiveness (OEE). These three aspects are closely related to enhancing company productivity in terms of production and sustainability. The study includes calculations of machine effectiveness using OEE and the assessment of company losses using the Six Big Losses framework. The results indicate that the average OEE over one year is 55%, which is below the international ideal standard and the company's target of 70%. Additionally, the sustainability index value obtained is 82.36%. Improvements are proposed based on the pillars of Total Productive Maintenance, focusing on safety, health, and environment, planned maintenance, and autonomous maintenance, all while considering sustainability aspects.  Furthermore, the study suggests enhancements to the 6S foundation within the company, adhering to sustainability aspects in line with SDG 12. By implementing a Total Productive Maintenance strategy that considers Safety, Health, and Environment, Planned Maintenance, and Autonomous Maintenance, and by advancing the 6S concept, the sustainability index value can be increased to 80.91%. Moreover, the effectiveness of the bending machine can be improved to 70.34%.