Lean Manufacturing Implementation to Reduce Waste Using the Waste Assessment Model Method in the Production Process

Abstract

The research carried out aims to identify, reduce, and hopefully eliminate waste on the Injection Phylon production line using the lean manufacturing concept. One of the tools in lean manufacturing, namely the Waste Assessment Model (WAM) is used to identify waste in the production process. Using the WAM method, it was found that inventory waste is a critical waste with a value of 21.41%, while the second place is defect waste with a value of 20.37% and the third is overproduction waste with a value of 17.49%. After calculating with WAM, calculations are performed using the Value Stream Analysis Tools (VALSAT) to assist in seeing the mapping of existing waste. Using the VALSAT method with the Process Activity Mapping tools, it is found that storage is the largest activity with a value of 85.63%. The critical waste found in this study using WAM and VALSAT is inventory waste. Based on the fishbone analysis, it is found that the root cause of inventory waste is due to the absence of a real-time work order (SPK) information system in the production section and there is no standard identification of manufactured goods. Key Words: Lean manufacturing, waste assessment model, value stream analysis tools, fishbone