Implementation of Lean Manufacturing Process to Reduce Waste: A Case Study

Abstract

Excessive waste production is often happening in the inefficient use of resources in manufacturing. There is still some excessive waste found in the electronic components company as a case study. It resulted from the careless use of resources and indirectly weakness their market positioning. The purpose of this paper is to present an implementation of a lean manufacturing process to reduce waste. This study aims to analyze and reduce the waste that occurs using lean manufacturing approaches. The value stream mapping (VSM) and waste relationship matrix (WRM) were applied to describe and to analyze the production flow of waste. Then, a waste assessment questionnaire (WAQ) is used to determine the percentage of waste that occurs. Value Stream Analysis Tools (VALSAT) is used for complete mapping tools. Three methods are considered for determining the feasibility, namely, net present value, internal rate of return, and profitability index. Base on analysis, we choose on the 3rd largest waste to be improved. According to the data analysis, it is found that increasing the number of production machines, carrying out appropriate maintenance activities, increasing training and supervision, and adding work facilities are recommendations for the improved production process. The proposed guidance seems to help the company reduce the seven waste and increase unit production. It is expected that the production process will be more effective and efficient.