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All Journal Jurnal Teknologi dan Manajemen Industri Terapan JPNM : Jurnal Pustaka Nusantara Multidisiplin Review: Journal of Multidisciplinary in Social Sciences Jurnal Sains dan Teknologi Jurnal Ragam Pengabdian Jejak digital: Jurnal Ilmiah Multidisiplin Scripta Technica: Journal of Engineering and Applied Technology Inventa: Journal of Science, Technology, and Innovation
Yudi Prastyo
Universitas Pelita Bangsa
Religion Agriculture, Biological Sciences & Forestry Humanities Automotive Engineering Chemical Engineering, Chemistry & Bioengineering Chemistry Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Economics, Econometrics & Finance Education Electrical & Electronics Engineering Engineering Environmental Science Industrial & Manufacturing Engineering Languange, Linguistic, Communication & Media Mechanical Engineering Physics Social Sciences Transportation Other

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Pengaplikasian 5S dan Kaizen Sebagai Upaya Peningkatan Kualitas Produksi Area Spot Welding di Perusahaan Manufaktur Otomotif Muhamad Tegar Maulana; Dwi Ayu Puspita Sari; Like Andreas Kindangen; Yusuf Eka Setiawan; Yudi Prastyo
Journal of Science, Technology, and Innovation Vol 1 No 2 (2025): December: Inventa: Journal of Science, Technology, and Innovation
Publisher : CV SCRIPTA INTELEKTUAL MANDIRI

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.65310/09hxkp86

Abstract

Improving production quality is one of the key factors in maintaining a company’s competitiveness, particularly in the manufacturing sector such as automotive and electronics. One approach that can be applied to achieve this efficiency is the 5R/5S method (Seiri, Seiton, Seiso, Seiketsu, and Shitsuke) and Kaizen, which focus on establishing an orderly, clean, and disciplined work culture as practiced in Japanese industries. This study aims to analyze the implementation of the 5S and Kaizen methods as an effort to improve the quality of the spot welding production process at PT.Manufacture Automotive. The research was carried out through field observations as an application of industrial theory in a real work environment. The methods used include direct observation, interviews, analysis of 5S implementation, and evaluation of conditions before and after improvements. Data were collected using a checklist audit sheet and analyzed descriptively to measure changes in efficiency and workplace organization. The results show that the implementation of the 5R/5S method successfully improved work quality and productivity. The 5S- condition assessment score increased from 22.24% (Not good category) to 67% (fair category) after the improvements were implemented.
Persepsi Karyawan Tentang Kesadaran K3 & Dampaknya Terhadap Proses Kerja di PT Breadcrumb X: Pendekatan 4M+1E Ria Sri Amelia; Revanza Fitra Hamdany; Sabilla Sholiah; Andry Putra Pratama; Yudi Prastyo
Journal of Science, Technology, and Innovation Vol 1 No 2 (2025): December: Inventa: Journal of Science, Technology, and Innovation
Publisher : CV SCRIPTA INTELEKTUAL MANDIRI

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.65310/ygbxk270

Abstract

Occupational safety and health (OSH) is a crucial aspect in ensuring smooth production processes and protecting workers, especially in the manufacturing industry, which has a high level of occupational risk. This study aims to analyze employees' perceptions of OSH awareness and its impact on work processes at PT Breadcrumb X using the 4M+1E approach. The research method used was descriptive qualitative, with data collection through in-depth interviews, field observations, and documentation of production employees and representatives of the OSH/SHE department. Data analysis was performed using the Miles and Huberman model through the stages of data reduction, data presentation, and conclusion drawing, with data validity maintained through source and method triangulation and member check. The results showed that employees had a basic understanding of K3, but its implementation was inconsistent due to limitations in training, PPE facilities, supervision, and the condition of machinery, work methods, materials, and the work environment, which were risky. These findings confirm that K3 awareness needs to be strengthened through management commitment, work system improvements, and active employee involvement in order to create a sustainable safety culture that supports the effectiveness of work processes..  
Analisis Pengendalian Risiko Korosi pada Material yang Disebabkan oleh Kelebihan Persediaan Menggunakan Metode Kanban Reduction Dony Bayu Leksono; Melco Wanjaya; Monika Lestari; Niki Farras Al Ghalidza Vannie; Yudi Prastyo
Journal of Science, Technology, and Innovation Vol 1 No 2 (2025): December: Inventa: Journal of Science, Technology, and Innovation
Publisher : CV SCRIPTA INTELEKTUAL MANDIRI

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.65310/ntd8ws85

Abstract

manufacturing systems. This condition causes materials to experience longer storage times, thereby increasing the risk of physical damage, especially corrosion of metal materials. This study aims to analyze the factors causing corrosion risks triggered by overstocking, and evaluate the implementation of Kanban Reduction as an inventory control strategy to reduce material exposure to corrosive environments. The methods used include field observation, measuring warehouse humidity levels, analyzing inventory before and after Kanban Reduction, and recalculating the number of kanban cards. The results show a decrease in WIP levels by 35.4%, a reduction in storage time from 14 to 6 days, and a decrease in scrap due to corrosion from 10.8% to 3.2%. These findings reinforce that Kanban Reduction is not only relevant for production flow efficiency but also for mitigating corrosion risks in materials. This study analyzes stock records using tools such as Fishbone diagrams and the 5S method. The study results showed that stock discrepancies were caused by incomplete in/out transactions, defective goods undergoing remelting, and unrecorded goods. Proposed improvements include implementing the 5S method to improve warehouse organization and stricter stock recording controls.
Implementation of Total Productive Maintenance (TPM) on Mitsui Seiki Compressors to Reduce Production Downtime Asep Hidayat; Suhendra Suhendra; Yudi Prastyo
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/gm0y0j61

Abstract

This study investigates the application of Total Productive Maintenance (TPM) to improve the performance of the Mitsui Seiki Inverter screw compressor at PT SEI. The research focuses on evaluating the compressor's Overall Equipment Effectiveness (OEE), which combines availability, performance, and quality metrics to assess the effectiveness of the equipment. Data collection involved primary data from observations and interviews with maintenance staff, along with secondary data from production records. The analysis employed TPM techniques, specifically focusing on reducing downtime and improving machine performance by addressing key issues such as nozzle blockages, cooling system failures, and fluctuating speed losses. The results revealed that the average OEE for 2025 was below the ideal standard of 85%, mainly due to performance losses and recurring breakdowns. The study highlights the importance of consistent maintenance, operational parameter control, and enhanced quality control practices. Recommendations include more frequent nozzle cleaning, regular checks of the cooling system, and implementing regular OEE monitoring as a Key Performance Indicator (KPI). The findings provide valuable insights into optimizing the maintenance of industrial compressors and improving overall production efficiency.
Downtime and Maintenance System Analysis of Reverse Osmosis (RO) Unit in a Beverage Manufacturing Company Ade Bagas Kusuma; Anggita Muhamad Maulana; Erwin Setiawan; Muhammad Rizki Abdul Aziz; Yudi Prastyo
Review: Journal of Multidisciplinary in Social Sciences Vol. 3 No. 05 (2026): May 2026
Publisher : Lentera Ilmu Nusantara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59422/rjmss.v3i05.1352

Abstract

This study aims to analyze downtime and maintenance systems in the Reverse Osmosis (RO) unit of a beverage manufacturing company. The research used a descriptive quantitative approach through direct observation, maintenance documentation, technician reports, and interviews with operators. The results showed that the RO unit experienced 31 hours of downtime during 720 hours of operation, with membrane fouling, clogged pre-treatment filters, high-pressure pump failure, and unstable water pressure identified as the main causes. The Mean Time To Repair (MTTR) was 2.58 hours, while the Mean Time Between Failures (MTBF) was 60 hours, with a machine availability rate of 95.69%. These findings indicate that although the RO unit is relatively reliable, the maintenance system still requires improvement, particularly in preventive maintenance scheduling and real-time monitoring. The implementation of PLC-based automation, PID control, and IoT-based monitoring is recommended to reduce downtime, improve operational efficiency, and maintain consistent water quality.
Integration of Statistical Process Control and Artificial Intelligence to Improve Steering System Process Capability in the NANO Model Bagus Pamungkas; Nailla Dwi Rizkia; Ridzqi Alfauji; Ahmad Syarifudin; Yudi Prastyo
Review: Journal of Multidisciplinary in Social Sciences Vol. 3 No. 05 (2026): May 2026
Publisher : Lentera Ilmu Nusantara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59422/rjmss.v3i05.1355

Abstract

The high Defects per Unit (DPU) in the NANO model, mainly caused by handlebar effort problems, indicates process variation in the steering system that affects product quality. This study aims to evaluate the stability and capability of the steering system production process and identify process parameters that contribute to handlebar effort through the integration of Statistical Process Control (SPC) and Artificial Intelligence (AI). Data were collected from measurements of steering system component dimensions and assembly process parameters on the production line. The analysis used X̄-R control charts, process capability indices, and a machine learning-based AI approach to detect abnormal patterns among process variables. The results show that the process is generally close to statistical control, but special cause variations are still found. Process capability analysis indicates that the process has not consistently met specifications, as shown by Cp = 0.87 and Cpk = 0.74. The main parameters affecting process performance are steering stem height 1 and head pipe height, both of which show high variation and low process capability. AI analysis also identified abnormal multivariate patterns related to these parameters. Therefore, improvements should focus on standardizing work procedures, calibrating measuring instruments, controlling materials, maintaining jig fixtures, and improving operator competence. The integration of SPC and AI supports more predictive quality control and helps reduce defects in the steering system production process.
Optimizing Manhour Productivity in Automotive Component Packing Process Using the ECRS Approach Ahmad Fauzi; Faqih Sidik Muttaqin; Muhammad Asyraf Hisyam Hidayat; Setiawan Laia; Yudi Prastyo
Review: Journal of Multidisciplinary in Social Sciences Vol. 3 No. 05 (2026): May 2026
Publisher : Lentera Ilmu Nusantara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59422/rjmss.v3i05.1363

Abstract

This study aims to improve manhour productivity in the packing process of an Indonesian automotive component company by applying the ECRS method (Eliminate, Combine, Rearrange, Simplify). The problem was identified from low labor productivity caused by non-value-added activities, inefficient work layout, non-ergonomic material placement, and the absence of proper work aids. A quantitative approach was used through direct observation, time study, motion analysis, fishbone diagram, and operation process chart to identify waste and determine improvement actions. The implementation of ECRS reduced the cycle time from 60 seconds to 46 seconds per unit, representing a 23.3% improvement, and increased output from 60 units/hour to 78 units/hour, equivalent to a 30% productivity increase. In addition, the improvement eliminated unnecessary movements, simplified work procedures, and enhanced ergonomic conditions for operators. The findings indicate that the ECRS approach provides a practical contribution to improving efficiency in manual packing processes without adding labor or major production equipment. Therefore, this method can be used as an effective and low-cost improvement strategy for productivity enhancement in manufacturing operations.
Operational Efficiency Optimization: Reducing Production Downtime through Fishbone Diagram Analysis and Trolley Shutter Implementation in an Indonesian Automotive Company Yunus Yunus; Rangga Arisandy; Fajar Dwi Prasetiyo; Yudi Prastyo
Jurnal Sains Dan Teknologi | E-ISSN : 3063-9980 Vol. 2 No. 4 (2026): April - Juni
Publisher : GLOBAL SCIENTS PUBLISHER

Show Abstract | Download Original | Original Source | Check in Google Scholar

Abstract

Production downtime poses a critical challenge in automotive manufacturing, exerting a direct influence on operational efficiency, line productivity, and corporate profitability. The present study was conducted at an Indonesian automotive company whose shutter production line recorded a downtime level of 15 hours per month (15%)—markedly exceeding the industry benchmark of 5 hours per month (5%). The objective was to systematically diagnose the root causes of this downtime and to design a measurable engineering intervention. The methodology combined a Fishbone (Ishikawa) Diagram structured around the 5M+1E framework—Man, Machine, Material, Method, Measurement, and Environment—with a Pareto analysis applied to six months of historical downtime records. The analysis revealed that the inefficient manual shutter-replacement procedure was the dominant contributor, accounting for 42% of total downtime. In response, a trolley shutter system—a mobile steel cart fitted with an adjustable lifting arm—was engineered and rolled out across four phases: prototyping, operator training, piloting, and full deployment. A six-month post-implementation evaluation demonstrated a statistically significant reduction in mean monthly downtime, falling from 15.0 ± 2.3 hours to 5.0 ± 1.1 hours, a 66.7% decrease (t(5) = 9.84; p < 0.001). The per-event shutter-replacement time likewise dropped from 47 minutes to 14 minutes. These findings confirm that pairing systematic root-cause analysis with a well-targeted engineering intervention constitutes an effective and quantifiable strategy for curbing production downtime in automotive manufacturing settings.
Penerapan Metode Root Cause Analysis (RCA) Dan Plan, Do, Check, Action (PDCA) Untuk Menurunkan Nilai Deadstock Pada Gudang  Spare Part Fajriyah Amanatus Sholikhah; Heru Darmawan; Yudi Prastyo
Jurnal Teknologi dan Manajemen Industri Terapan Vol. 5 No. 3 (2026): Jurnal Teknologi dan Manajemen Industri Terapan
Publisher : Yayasan Inovasi Kemajuan Intelektual

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.55826/jtmit.v5i3.1971

Abstract

Deadstock pada gudang spare part manufaktur memicu inefisiensi finansial akibat pembekuan modal kerja dan pembengkakan biaya penyimpanan. Penelitian ini bertujuan untuk menganalisis faktor penyebab utama munculnya deadstock spare part di PT. XYZ serta merancang tindakan perbaikan terstruktur. Metode penelitian yang digunakan adalah pendekatan deskriptif-kuantitatif dengan mengintegrasikan metode Root Cause Analysis (RCA) melalui Fishbone Diagram dan 5 Whys Analysis ke dalam siklus Plan, Do, Check, Action (PDCA). Data finansial awal (baseline) dipetakan ke dalam empat kategori kekritisan, di mana kategori Critical Part mendominasi akumulasi kerugian terbesar yaitu senilai Rp 199.173.000 (45,64%) dari total deadstock awal sebesar Rp 436.436.000. Hasil analisis RCA mengidentifikasi bahwa akar penyebab utama masalah dipicu oleh metode pemesanan ulang yang belum matematis, ketiadaan sistem monitoring otomatis, serta diskoneksi data antara jadwal perawatan mesin dengan pengadaan. Rencana tindakan perbaikan dirancang menggunakan matriks 5W+1H. Implementasi perbaikan dilakukan melalui penerapan Safety Stock dan Reorder Point, pembuatan dasbor pengendalian visual berbasis traffic light system, serta eksekusi disposal. Hasil evaluasi menunjukkan penurunan akumulasi nilai finansial deadstock yang sangat drastis dari Rp 436.436.000 menjadi Rp 50.020.017, menghasilkan selisih penurunan sebesar Rp 386.415.983 dengan tingkat persentase efektivitas perbaikan tata kelola final mencapai 88,54%. Pada tahap Action, keberlanjutan perbaikan dikunci melalui standardisasi draf Standard Operating Procedure (SOP) kontrol inventaris baru, klasifikasi ketat terhadap 2.401 item material, dan integrasi alur persetujuan berlapis (approval workflow).
Analisis Penyebab Defect Pada Part Electric Dalam Proses Incoming Inspection Yoga Pratama; Heru Darmawan; Yudi Prastyo
Jurnal Teknologi dan Manajemen Industri Terapan Vol. 5 No. 3 (2026): Jurnal Teknologi dan Manajemen Industri Terapan
Publisher : Yayasan Inovasi Kemajuan Intelektual

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.55826/jtmit.v5i3.1974

Abstract

Kualitas part electric yang diterima pada proses incoming inspection merupakan faktor penting dalam menjaga kelancaran proses produksi dan kualitas produk akhir. Penelitian ini bertujuan mengidentifikasi jenis defect dominan, menganalisis faktor penyebab, serta menyusun usulan perbaikan pada proses incoming inspection part electric di PT XYZ menggunakan metode Seven Quality Control Tools. Metode penelitian yang digunakan bersifat deskriptif kuantitatif dengan memanfaatkan data primer melalui observasi dan wawancara serta data sekunder berupa laporan incoming inspection, Standard Operating Procedure (SOP), dan Work Instruction. Analisis dilakukan menggunakan Check Sheet, Histogram, Diagram Pareto, Scatter Diagram, Flowchart, Control Chart, dan Fishbone Diagram. Hasil penelitian menunjukkan bahwa defect Under Spec Length pada Power Cord merupakan jenis defect yang paling dominan dengan jumlah 83 pcs (29,86%), diikuti Label Printing Faded sebanyak 50 pcs (17,99%), No Power sebanyak 45 pcs (16,19%), Missing Tapping sebanyak 43 pcs (15,47%), Missing IMS sebanyak 32 pcs (11,51%), dan No Sound sebanyak 25 pcs (8,99%). Scatter Diagram menunjukkan hubungan yang lemah antara jumlah PCS/LOT dengan persentase defect, sehingga tingginya defect lebih dipengaruhi oleh kualitas material, metode inspeksi, ketelitian inspector, dan kondisi proses sebelumnya. Fishbone Diagram mengidentifikasi faktor penyebab utama berasal dari aspek man, method, material, machine, dan environment. Berdasarkan hasil analisis tersebut, diusulkan beberapa tindakan perbaikan berupa pelatihan inspector, standarisasi SOP, penggunaan checklist inspection, evaluasi supplier, kalibrasi alat inspeksi, serta perbaikan area kerja melalui peningkatan pencahayaan dan penerapan prinsip 5R. Penelitian ini diharapkan dapat menjadi dasar bagi PT XYZ dalam meningkatkan efektivitas proses incoming inspection, menurunkan jumlah defect, serta mendukung perbaikan kualitas secara berkelanjutan.
Co-Authors Ade Bagas Kusuma Ade Surya Rachmawan Ahmad Fauzi Ahmad Syarifudin Aldi Ilham Saputra Andry Putra Pratama Anggita Muhamad Maulana Ariel Dwi Putra Asep Hidayat Asroni Asroni Bagus Pamungkas Bayu Putra Nur Pratama Dony Bayu Leksono Dwi Ayu Puspita Sari Erwin Setiawan Fajar Dwi Prasetiyo Fajriyah Amanatus Sholikhah Faqih Sidik Muttaqin Ferdian Setia Nugraha Fernanda Aprian Firman Firdaus Hamzah Sodikin Heru Darmawan Hilman Mubarik Aziz Ikhsan Dwi Nugroho Immanuel Wijaya Huwae Like Andreas Kindangen M. Khafid Ramadhon Melco Wanjaya Monika Lestari Muhamad Tegar Maulana Muhammad Asyraf Hisyam Hidayat Muhammad Ibel Muhammad Ifdol Muhammad Rizki Abdul Aziz Nailla Dwi Rizkia Niki Farras Al Ghalidza Vannie Rangga Arisandy Reno Agusto Revanza Fitra Hamdany Reza Kholil Yusni Ria Sri Amelia Ridzqi Alfauji Rismawati Pebriani Rizal Deokosta Rizky Febriansyah Rossy Ruwandra Sabilla Sholiah Setiawan Laia Suhendra Vicky Adni Firmansyah Wahyu Darmawan Yoga Pratama Yunita Yunita Yunus Yunus Yusuf Eka Setiawan Yusup Purnomo