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All Journal Journal of Industrial Engineering Innovation Indonesian Journal of Engineering and Technological Innovation
Permadi, Rama
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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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Application of Poka-Yoke and Kanban Methods to Improve Shoe Production Efficiency At PT.xyz Twonando, Ficky; Permadi, Rama; Hakim, Achmad Luqman; Arnanda, Halif Tri; Ardiansah, Arki
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.v1i3.394

Abstract

This study aims to examine how the application of the Poka-Yoke and Kanban methods can improve production process efficiency at PT. XYZ, a hypothetical shoe company simulated using dummy data. In this simulation, daily production capacity is set at 1,000 pairs of shoes with an initial defect rate of 5% and a Work in Process (WIP) quantity of 1,000 pairs. The results show that the implementation of Poka-Yoke, which serves to prevent human error during the production process, successfully reduced the defect rate to only 0.1% and saved approximately Rp 73,500,000 per month. Meanwhile, the implementation of Kanban, which focuses on controlling material flow and inventory efficiency, was able to reduce the number of WIP by 70% and generate savings of around Rp 210,000,000 per month. Financial analysis shows a Return on Investment (ROI) of 782% for Poka-Yoke and 4,940% for Kanban, meaning that both methods are highly profitable. When applied simultaneously, they also increase the number of finished products (throughput) by 18.75%. Overall, this study demonstrates that the combination of Poka-Yoke and Kanban can be an effective strategy for reducing waste, minimizing product defects, and improving productivity in the modern shoe industry.
Penerapan Metode Poka-Yoke dan Kanban untuk Meningkatkan Efisiensi Produksi Sepatu di PT. XYZ Fiky Two Nando; Permadi, Rama; Luqman Hakim, Achmad; Tri Arnanda, Halif; Ardiansah, Arki
Journal of Industrial Engineering Innovation Vol. 4 No. 01 (2026): April 2026
Publisher : Insight Publisher, Makassar, Indonesia

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Abstract

Penelitian ini bertujuan mengeksplorasi penerapan metode Poka-Yoke dan Kanban pada perusahaan sepatu hipotetis PT. XYZ menggunakan data dummy sebagai pendekatan simulatif. Data yang digunakan meliputi produksi harian sebesar 1.000 pasang sepatu, tingkat cacat awal 5%, dan work in process (WIP) sebanyak 1.000 pasang. Hasil simulasi menunjukkan bahwa implementasi Poka-Yoke mampu menurunkan tingkat cacat secara signifikan hingga 0,1% serta menghasilkan penghematan biaya sebesar Rp 73.500.000 per bulan. Sementara itu, penerapan Kanban berhasil mengurangi WIP sebesar 70% dengan penghematan mencapai Rp 210.000.000 per bulan. Analisis finansial menunjukkan nilai return on investment (ROI) sebesar 782% untuk Poka-Yoke dan 4.940% untuk Kanban. Integrasi kedua metode tersebut juga terbukti meningkatkan throughput produksi sebesar 18,75%. Meskipun berbasis data simulasi, penelitian ini memberikan gambaran kuat bahwa pendekatan lean manufacturing berpotensi meningkatkan efisiensi operasional, kualitas produk, dan kinerja finansial secara signifikan dalam industri manufaktur sepatu
Co-Authors Ardiansah, Arki Arnanda, Halif Tri Fiky Two Nando Hakim, Achmad Luqman Luqman Hakim, Achmad Tri Arnanda, Halif Twonando, Ficky