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All Journal Indonesian Journal of Engineering and Technological Innovation
Nando, Fiky Two
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Aerospace Engineering Chemical Engineering, Chemistry & Bioengineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Electrical & Electronics Engineering Engineering Industrial & Manufacturing Engineering Mechanical Engineering Transportation

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Efforts to Improve the Quality of Shrimp Pasted Products through the Implementation of the Plan-Do-Check-Act Cycle and the Root Cause Analysis Method  at UD Nurhayati Nando, Fiky Two; Avnanta Puteri, Agatha Hannabel; Qinthara, Bahij Naufal; Fernandy, Dimas Rizah; Kurniawan, Aditya Fahrizal; Alfani, Achmad Hafis
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 2 (2025): June: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i2.377

Abstract

Micro, Small, and Medium Enterprises (MSMEs) play a vital role in the economy. However, MSMEs often face challenges in maintaining product quality due to limited machinery and suboptimal production process control, leading to losses. One example is the production of shrimp paste at UD Nurhayati, with a capacity of approximately 3 dozen cups per month. Defective products were found due to poorly controlled processing. These defects included uneven shrimp paste texture and high humidity levels that could potentially lead to mold growth. This study aimed to identify the root cause of problems in the production line using the Root Cause Analysis (RCA) method, followed by improvements through the implementation of the Plan, Do, Check, and Action (PDCA) cycle to assist UD Nurhayati in addressing defective products. Based on the results of the application of these methods, this study produced several outcomes, namely a significant reduction in the number of defective products and an increase in production capacity of 33.3% and 14.95%, respectively, compared to the condition before the improvements were made. This study indicates that the application of the PDCA and RCA methods can improve the quality and effectiveness of the production process. These results imply that UD Nurhayati needs to standardize work procedures and provide ongoing training for employees to maintain consistent product quality.
Optimizing the Production of Micro, Small, and Medium Enterprises Using  the Heijunka Method and Single Minute Exchange of Dies Nando, Fiky Two; Liwaq, Moch Isabil; Rizki, Muhamad Farhan; Pambudi, Vava Surya; Friski, Auviano Bidana
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 2 (2025): June: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i2.378

Abstract

Micro, Small, and Medium Enterprises (MSMEs) producing bags often face production challenges such as long setup times, unbalanced workloads, and excessive inventory, which reduce efficiency and productivity. This study aims to optimize the production process by applying the Heijunka and Single Minute Exchange of Dies (SMED) methods as part of the Lean Manufacturing approach. The analysis was conducted quantitatively based on actual production data of three types of bags over 27 working days with 13 workers and 8 working hours per day. The results show that the Heijunka method successfully leveled production variation into a daily combination of 30 units of Bag A, 33 units of Bag B, and 14 units of Bag C, resulting in a more stable workflow and reduced overproduction. The application of SMED reduced setup time from 1,560 minutes to 327.6 minutes per month, achieving 79% efficiency improvement, and decreased utilization from 105.36% to 102.6%. These findings indicate that the combination of Heijunka and SMED is effective in improving efficiency, flexibility, and production stability in bag SMEs without requiring significant investment, while enabling the company to meet customer demand on time.
Analysis of the Application of Just in Time and Total Productive Maintenance on Production Efficiency at CV XYZ Nando, Fiky Two; Bintang Pamungkas, Mohammad Rafly Rafsyanjani; Kusuma, Febiola Alyza; Ramadan, Prananda Aditia; Sautra, Tri Wahyu; Saputra, Mohamad Risfi
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 2 (2025): June: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i2.380

Abstract

This study aims to evaluate the implementation of the Just-In-Time (JIT) and Total Productive Maintenance (TPM) methods as an effort to improve production process efficiency at CV XYZ, a metal manufacturing company located in East Java. The research approach was conducted through a case study utilizing primary data, including raw material requirements, ordering and storage costs, machine downtime duration, and product defect percentage. The analysis involved calculating the Economic Order Quantity (EOQ) and Reorder Point (ROP) to determine an optimal raw material procurement strategy, as well as measuring Overall Equipment Effectiveness (OEE) to assess machine performance before and after TPM implementation. Based on the analysis results, the application of JIT produced an EOQ value of 200 tons per order and an ROP value of 280 tons, which led to a reduction in total inventory costs from IDR 135,000,000 to IDR 108,000,000 per year, representing an efficiency improvement of approximately 20%. Meanwhile, TPM implementation increased the average OEE value from 78% to over 85%, accompanied by a decrease in machine downtime and product defect rates. The integration of JIT and TPM proved effective in creating a more consistent production system, reducing the need for safety stock, and improving process reliability and cost efficiency. Overall, the combined implementation of these two methods contributes significantly to enhancing operational efficiency and product quality, making it a potential model for other manufacturing companies in sustainable inventory management and machine maintenance practices.
Analysis of Production Process Improvement on Automatic Bolt Forming Machine Using Value Stream Mapping and FMEA Approach Nando, Fiky Two; Ivander, Davin Danny; Sharren, Desti Sagita; Yudhistira, Christoforus; Remadaniel, Hilbram; As Shidiq, Mashudan; Sari, A.Anditha
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 2 (2025): June: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i2.381

Abstract

This study aims to analyze the production efficiency of an automatic bolt forming machine at PT XYZ using the Value Stream Mapping (VSM) and Failure Mode and Effect Analysis (FMEA) approaches. The Lean Manufacturing concept was applied to identify non-value-added activities and potential failures affecting production quality. Data were collected through direct observation, cycle time measurement, and interviews with operators and supervisors over a three-month period. The VSM results indicate that the total process time of 20,304 seconds consists of 75.64% value-added activities, 11.97% non-value-added activities, and 12.40% necessary but non-value-added activities. These findings show that efficiency improvements are still possible by minimizing non-value-adding processes. The FMEA analysis revealed the highest Risk Priority Number (RPN) of 147, occurring in the forming stage with failures such as improper heading, inaccurate trimming, and die damage. The study concludes that combining VSM and FMEA provides an effective framework for assessing process performance and determining improvement priorities to enhance efficiency and reduce product defects
Implementation of Kanban and Poka-Yoke to Improve Production Efficiency at CV. XYZ Nando, Fiky Two; Priyangga, Dharu Zastia; Ramadhani, Akbar; Afnan Fairuz, Ferdian Nizar; Armalia, Aqillah; Putri, Katerina Najwa
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 2 (2025): June: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i2.382

Abstract

XYZ is a household plastic components manufacturer facing elevated defect rates (4–5% daily), accumulation of work-in-process (WIP) in the cooling area, and recurring labeling errors during packaging. This study evaluates the combined application of Kanban as a pull-based material flow control and Poka-Yoke as simple error-proofing devices to improve production efficiency and product quality. A quantitative descriptive approach was employed, using direct observation, time-and-motion measurements, interviews with operators and supervisors, and before–after comparisons of key performance indicators. Kanban sizing was calculated using D = 125 units/hour, L = 4 hours, S = 0.1, and container capacity C = 50 units, yielding an optimal 11 Kanban cards. Poka-Yoke implementations included automatic temperature alarms on molding machines, fixture sensors at finishing stations, and barcode-based label verification at packaging. After implementation, WIP decreased from 280 to 150 units (−46%); inter-process waiting time reduced from 45 to 20 minutes (−56%); daily output increased from 800 to 950 units (+18.7%); defect rate declined from approximately 5% to 1.8%; and labeling errors were eliminated. The results indicate that integrating Kanban and Poka-Yoke can effectively streamline production flow, reduce waste, and enhance productivity in small-to-medium plastic manufacturing operations. Implications, limitations, and recommendations for broader application are discussed.
Penerapan Metode Value Stream Mapping dan 5S untuk Meningkatkan Cycle Time Proses Produksi Sepatu pada UD. XYZ Nando, Fiky Two; Ilmanzani, Latisha Aura; Yunanda, Fitrah; Permatasari, Shinta Naafia; Izulhaq, Muhammad Nabil; Bua, Febrianto Taruk
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 3 (2025): September: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i3.383

Abstract

UD. XYZ is one of the trading businesses that produces shoes with a simple working system. The production process is still dominated by activities that take a considerable amount of time due to the lack of standardized work and the high number of activities that do not directly add value to the product. This condition causes the total production time to be long and work efficiency to decrease. Therefore, this research aims to reduce cycle time and improve the efficiency of the shoe production process by identifying waste and applying Value Stream Mapping (VSM), Process Activity Mapping (PAM) methods, and implementing the 5S principles for improvement efforts. Based on the analysis results of the Current State Map and PAM, the total production time is 5,760 seconds, with most of it being necessary non-value added (NNVA) activities. After implementing improvement efforts using the 5S principles, the process and picking times, which previously took a long duration, were successfully reduced, resulting in a decrease in cycle time to 5,030 seconds, or an efficiency improvement of 12.6%. This result was achieved by adding supporting tools and machines and implementing improvements to the work system at UD. XYZ. Thus, the combination of the VSM method and the 5S principles proved effective as an improvement strategy for optimizing production performance.
Analisis Waste Pada Produksi Sari Kedelai Di UMKM XYZ Menggunakan Pendekatan Value Stream Mapping dan 5 Why Analysis Nando, Fiky Two; Mayangsari, Adhindha Putri; Nursyabani, Inayah Aulia; Nurul, Sazhana; Ratih, Dwi; Ivan, Michael
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 3 (2025): September: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i3.387

Abstract

Production process efficiency is a crucial factor for micro, small, and medium enterprises (MSMEs) in enhancing competitiveness within the food industry sector. However, many MSMEs still face obstacles such as non-value-added activities (waste), including waiting time and inefficient material handling. This research aims to analyze and improve the production process of soybean juice at SME XYZ using the Value Stream Mapping (VSM) and 5 Whys methods. The VSM method is used to map the value stream in the production process in order to identify value-added activities, non-value-added activities, and necessary non-value-added activities. Meanwhile, the 5 Whys method is used to find the root causes of waste occurring on the production floor. The analysis results show that the main waste occurs in waste transportation and waste motion due to inefficient production layout and the absence of standard operating procedures. After improvements were made using the U-shaped layout design, there was a decrease in Non-Value Added activity time from 4,468 seconds to 2,270 seconds, and a decrease in lead time from 10,848 seconds to 8,650 seconds. Thus, the application of the VSM and 5 Whys methods proved effective in improving process flow efficiency and reducing waste in the production of soybean milk at UMKM XYZ.
Production Afalan Analysis Using Value Stream Mapping (VSM) and Root Cause Analysis (RCA) Methods at PT. XYZ Nando, Fiky Two; Anindya, Salsabila; Sarodin, Moc. Bah; Kennedy, John; Satya P, Akbar; Yusuf, Adam
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 3 (2025): September: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i3.391

Abstract

The competitiveness of the manufacturing industry demands companies to enhance production efficiency and reduce product defects. PT. Kerta Rajasa Raya, a woven bag manufacturing company, faces a high level of production scrap (defects), which decreases productivity and increases production costs. This study aims to analyze the defect rate, identify process waste using the Value Stream Mapping (VSM) approach, and determine the root causes of major defects through Root Cause Analysis (RCA). The research employs a descriptive case study method using secondary data from production and defect reports from January to June 2025. The results show that the total defect rate reached 3.44%, with the dominant defect being setting at 0.56% of total production. Based on the VSM mapping, the main wastes occur in the printing and cutting processes due to the absence of a standard operating procedure (SOP) for machine setting, long waiting times, and repeated rework. RCA analysis revealed that the root causes stem from insufficient operator training, machine wear, and variations in raw material quality. Improvement through the future state map, including the implementation of SOPs, kanban system, and operator training, led to a 52% improvement in process efficiency and a 50% reduction in defect rate. This study demonstrates that the integrated application of VSM and RCA is effective in identifying waste and improving production performance in manufacturing industries.
Analisis Waste Pemotongan Material Plate Menggunakan Metode Value Stream Mapping (VSM) dan Root Cause Analysis (RCA) di PT. YYY Nando, Fiky Two; Pamungkas, Ferio Aji; Ardiansyah, M. Dava; Febriyanti, Amalia Rizka; Subrakah, Bagas; Mawadati, Argaditia
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 3 (2025): September: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i3.416

Abstract

This research was conducted at PT. YYY, a manufacturing company engaged in fabrication with a focus on the plate cutting process, which plays an important role in determining the accuracy, precision, and quality of production results. However, various problems were still found such as cutting defects, inappropriate dimensions, and deformation due to heat that caused rework and wasted time and costs. To overcome this, this study applied the Root Cause Analysis (RCA) and Value Stream Mapping (VSM) methods to identify the root causes of defects and non-value added activities (Non-Value Added). The results of the analysis showed a total of Non-Value Added (NVA) of 80 minutes and a waiting time of 130 minutes, with the main causes coming from the Man, Method, Machine, Environment, and System aspects. Through the implementation of improvements such as work standardization, measuring instrument calibration, area layout arrangement, and digitalization of the material monitoring system, increased efficiency, reduced waste, and improved overall production quality and timeliness were achieved.
Penerapan Prinsip 5S dalam Meningkatkan Efisiensi dan Mengurangi Waste Montion Pada PT. XYZ dengan Pendekatan Lean Manufacturing Nando, Fiky Two; Ramadhan, Muhammad Ilham; Wicaksono, Rendy Bagus; Cahyani, Andini Putri; Anindita, Imara Hany; Prabandari, Anggraeni Sih
Indonesian Journal of Engineering and Technological Innovation Vol. 1 No. 4 (2025): December: Indonesian Journal of Engineering and Technological Innovation
Publisher : Yayasan Cendekia Gagayunan Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.63142/ijeti.v1i4.419

Abstract

PT. XYZ is a company engaged in the furniture industry, with one of its main products being wooden doors, which serve as the object of analysis in this final project. Based on historical data from June 2025 to October 2025, there is a gap between the actual production output and the company’s target. This shortfall is indicated to be caused by waste occurring throughout the production process. Through the lean manufacturing approach, the types and causes of waste were identified using Value Stream Mapping (VSM) and Process Activity Mapping (PAM). The mapping results show a total production lead time of 4,320 seconds and reveal the presence of Non-Value-Added (NVA) activities that affect production performance. The waste with the highest percentage is motion waste, accounting for 66%, which becomes the focus of this study. The root causes of motion waste were analyzed using the 5 Whys method to determine the source of activities that do not add value. Based on the results of this analysis, improvement plans were developed through the implementation of 5S activities (seiri, seiton, seiso, seiketsu, and shitsuke) to minimize motion waste. The implementation of the proposed improvements shows that the total lead time has the potential to decrease and can be further enhanced through continuous kaizen efforts.
Co-Authors Afnan Fairuz, Ferdian Nizar Alfani, Achmad Hafis Anindita, Imara Hany Anindya, Salsabila Ardiansyah, M. Dava Argaditia Mawadati Armalia, Aqillah As Shidiq, Mashudan Avnanta Puteri, Agatha Hannabel Bintang Pamungkas, Mohammad Rafly Rafsyanjani Bua, Febrianto Taruk Cahyani, Andini Putri Febriyanti, Amalia Rizka Fernandy, Dimas Rizah Friski, Auviano Bidana Ilmanzani, Latisha Aura Ivan, Michael Ivander, Davin Danny Izulhaq, Muhammad Nabil Kennedy, John Kurniawan, Aditya Fahrizal Kusuma, Febiola Alyza Liwaq, Moch Isabil Mayangsari, Adhindha Putri Nursyabani, Inayah Aulia Nurul, Sazhana Pambudi, Vava Surya Pamungkas, Ferio Aji Permatasari, Shinta Naafia Prabandari, Anggraeni Sih Priyangga, Dharu Zastia Putri, Katerina Najwa Qinthara, Bahij Naufal Ramadan, Prananda Aditia Ramadhan, Muhammad Ilham Ramadhani, Akbar Ratih, Dwi Remadaniel, Hilbram Rizki, Muhamad Farhan Saputra, Mohamad Risfi Sari, A.Anditha Sarodin, Moc. Bah Satya P, Akbar Sautra, Tri Wahyu Sharren, Desti Sagita Subrakah, Bagas Wicaksono, Rendy Bagus Yudhistira, Christoforus Yunanda, Fitrah Yusuf, Adam