Re-design Production Process Using Lean Manufacturing Approach for Pressure Vessel 421 Psi

Abstract

In order to become more competitive, the terms of improving quality, productivity and efficiency while reducing production costs is a challenge that must be faced by all manufacturing industries. Implementation of lean manufacturing (LM) can be made by doing simple changes to the previous process for future processes. Traditionally, strategies to achieve cost reduction are only made with improvements from the perspective of operational efficiency using LM. This study aims to present an overview of the simplification and trimming workflows that going to re-design the flow process. The objects observed were fabrication process of shell with design pressure 421 Psi. Firstly, mapping the process using current state mapping, identified the highest percentage of non-value added activity (NVA) using process activity mapping (PAM), then minimized and or eliminated with improvements propose to a product design that is analysed using design for manufacturing and assembly (DFMA) approach. From the improvements propose, it was found that manufacturing costs could be reduced until 103 million rupiah and lead time reduced by 13.5 days from 19 days to become 5 days, also a future state map of improvements proposed that have been given.