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All Journal Jurnal Teknologi dan Riset Terapan (JATRA) Jurnal Teknik Industri Terintegrasi (JUTIN)
Irma Agustiningsih Imdam
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Aerospace Engineering Computer Science & IT Decision Sciences, Operations Research & Management Electrical & Electronics Engineering Energy Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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IDENTIFIKASI WASTE DEFECT DENGAN VALSAT DAN PEMBUATAN JADWAL MAINTENANCE UNTUK MENINGKATKAN AVAILABILITY DAN MENGURANGI DEFECT. Irma Agustiningsih Imdam; Muhammad Aqsho; Juliansyah Aristama; Nico Sachzehan
Jurnal Teknologi Dan Riset Terapan (JATRA) Vol. 7 No. 2 (2025): Jurnal Teknologi dan Riset Terapan (JATRA) - December 2025
Publisher : Politeknik Negeri Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30871/jatra.v7i2.10985

Abstract

This research aims to identify and minimize waste in the join maple production process at PT MNO, an IKM (small and medium industry) company operating in the automotive component sector. A lean manufacturing approach was applied using Value Stream Mapping (VSM) to analyze the overall production flow. Furthermore, a Waste Assessment Questionnaire (WAQ) followed by a Waste Relationship Matrix (WRM) was used to determine the most dominant type of waste. The results indicate that defect waste is the main problem, leading to increased production time due to additional rework activities. Three types of defects were identified in join maple products, namely burnt defects, small head dimensions, and burr defects. The VALSAT approach using Quality Filter Mapping (QFM) revealed that burr defects were the most dominant, occurring in the cutting process at a rate of 1.26%, exceeding the company standard of 1%. Based on fishbone diagram analysis, the main causes of burr defects include corrective maintenance practices, the absence of a periodic tool replacement schedule, and weak implementation of the 5S/5R culture. The proposed improvements include daily tool inspections as preventive maintenance, the use of inspection check sheets, scheduled tool replacement, and the application of jidoka. The results show that the defect rate decreased from 1.26% to 0.88%, availability increased from 88% to 94%, performance efficiency rose from 63.76% to 80%, and quality improved from 98.73% to 99.34%, resulting in a 19.55% increase in Overall Equipment Effectiveness (OEE).
Integrasi MRP dan RCCP untuk Perencanaan Pengadaan Komponen dan Evaluasi Kapasitas Produksi pada Bengkel YY Exhaust Irma Agustiningsih Imdam; Nabila Wahyu Ramadhaniarti; Muhammad Arief Naufal; Muhammad Luthfi Alif; Dianasanti Salati
Jurnal Teknik Industri Terintegrasi (JUTIN) Vol. 9 No. 4 (2026): October
Publisher : LPPM Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/jutin.v9i4.62038

Abstract

YY Exhaust Workshop faces challenges in managing component inventory and lacks a clear picture of its production capacity. This study integrates Material Requirement Planning (MRP) and Rough Cut Capacity Planning (RCCP) as a basis for component procurement planning and production capacity evaluation. MRP compares six lot sizing techniques (LFL, EOQ, POQ, LUC, LTC, PPB) to determine the most cost-efficient procurement method, while RCCP evaluates production capacity adequacy using the Bill of Labour Approach (BoLA). MRP results show that the PPB technique produces the lowest total inventory cost of Rp571,916.13. RCCP results show that all work stations are in an underload condition, with the highest effectiveness at the assembly station of 57.76% and the lowest at the cutting station of 0.96%, indicating that production capacity is sufficient without requiring any capacity adjustments.
Co-Authors Dianasanti Salati Juliansyah Aristama Muhammad Aqsho Muhammad Arief Naufal Muhammad Luthfi Alif Nabila Wahyu Ramadhaniarti Nico Sachzehan