The reduction of waste on pile production process using value stream analysis tool (VALSAT) method

Abstract

This paper discusses about the reduction of waste on the pile production process in PT. XYZ, a company that run its business in the field of engineering, production installation (EPI) of a concrete industry. The methods of data collection are observation and interview. The analysis that will be employed is Value Stream Analysis Tool (VALSAT). Based on the value stream mapping, it is identified that the cycle time data for product’s manufacturing is 5.847 seconds with lead time of 1.380 seconds. Based on the result of observation and interview, it is identified that the biggest waste is resulted from the waste of excessive transportation. The movement process is executed on the same workstation and among workstations. While, the result of process activity mapping indicates that 27,6% of all activities are included in transportation activities. By conducting the mapping using fishbone diagram, later could be identified the factors that influence waste, in which, from human resource perspectives, it is caused by the less-evenly workers distribution at line 2 on pile production, unbalance production process that causes idle time or idled operators, the lack of understanding and workers’ skill on machine utilization as well in handling the problems. In the perspective of method, the issue lies on layout factors and 5S system that runs inappropriately at line two. In terms of machine, it is stressed on the lack of numbers of tools or machines as well as the less upgraded machines. From the perspective of environment, rain definitely could affect the condensation maintaining process and evaporation.