Implementation of Lean Manufacturing to Reduce Hold Types of Mission Case Products using DMAIC and KAIZEN Approach

Abstract

Company in this research is a manufacturing company engaged in the automotive industry that produces transmissions for four-wheeled vehicles. This research was conducted at the ALMC department which specializes in producing Mission Cases. In carrying out this Mission Case production activity, it is still found that there are Hold defects or pending parts because the quality does not meet the requirements to be flowed in the assembly process. The types of defects are kizu (berets), dakon (dented due to impact) and atsukon (dented due to scrap.) As a result, the company has to incur additional costs to repair the part (overprocess)so that it can be transferred to the assembly process. The purpose of this research is to minimize the Hold defects by implementing lean manufacturing through DMAIC and KAIZEN approaches. The identification of waste in the production line is carried out using value stream mapping tools and the Hold defect problem analysis stage is solved using DMAIC tools. The results of this study are expected to minimize smallpox hold with the implementation of lean manufacturing