Value Stream Analysis Tools Research Articles

Identifikasi Pemborosan dalam Proses Produksi Pakan Ternak Ayam di PT.XYZ dengan Menggunakan Metode Value Stream Analysis Tools (VALSAT)

This research aims to identify various types of waste in the chicken feed production process at PT. XYZ and provide improvement recommendations to reduce production costs. The method used is the Value Stream Analysis Tools (VALSAT) to map and analyze the value stream in the production process. This research includes direct observation and data analysis to find the main wastes. The results show seven main types of waste in the chicken feed production process: waiting time, unnecessary movements, product defects, excess inventory, inefficient processes, overproduction, and transportation. However, the research encountered several challenges, such as data limitations and difficulties in collecting accurate data. The largest waste found was excess inventory, with an average score of 9.13. This research provides clear insights into areas in the production process that require improvement. The implementation of the improvement recommendations is expected to increase the company's efficiency and productivity. Despite facing some challenges, the use of VALSAT proved effective in identifying and analyzing waste. It is hoped that the provided improvement recommendations can reduce waste and enhance operational efficiency at PT. XYZ.

Implementation of Lean Construction to Reduce Waste with the Value Stream Analysis Tools (VALSAT) Method in the Project Casting Process

This study aims to identify waste that occurs in the casting process of the project carried out by CV. Wishitama using value stream analysis tools (VALSAT) and provide suggestions for improvements with fishbone diagrams for the casting process of the project carried out by CV. Wishitama. This study uses a qualitative approach and case study with value stream analysis tools (VALSAT) and fishbone diagram analysis. The results of this study are that there are four types of waste that are prioritized for elimination, namely, overprocessing, defective products, queues, and motion. This study will provide new contributions to knowledge in the field of lean construction, with a focus on the construction industry. The results of this study will complement existing knowledge and provide new insights into how the application of lean construction can eliminate waste in the construction industry. Companies can eliminate and be effective in waiting for heavy equipment (readymix and concrete pumps) and vibrating equipment during casting. In addition, companies can increase direct supervision, conduct additional training, conduct evaluations, implement a reward or punishment system according to employee performance, plan efficient schedules, assign employees according to needs, and conduct outreach on current employee performance as a form of effort to improve human resources.

Enhance Productivity In The Garment Industry Through A Modified Value Stream Mapping Approach

The objective of this study is to overcome problems that occur in the garment industry, the company has tried to develop an agile system to increase productivity in this industry. The garment company that focusses on the production of woven bottoms and outerwear, noted that women's woven bottoms products have the highest demand throughout 2022. However, the company was unable to meet Brand demand of 3.5%. Production data shows defects in products, low quality raw materials, and unstable production processes. A modified Value Stream Mapping (VSM) methodology is use to consider all aspects of production. The results of traditional VSM and Value Stream Analysis Tools (VALSAT) analysis include current state and future state, identification of value added and non-value-added elements during the production process, as well as setting priorities to reduce waste in the production process, especially in inventory (19%), defective parts (17%), and transportation (15%). Based on the VALSAT matrix, Process Activity Mapping (33.5%), Supply Chain Response Matrix (21.6%), and Demand Amplification Mapping (15.3%) were obtained. The findings of this research are Pilot Run, which succeeded in becoming an agile and reliable system during the production process. Through the application of the methodology combined with VSM the results have improved compared to the traditional VSM method. This proves that this method is effective in overcoming takt time, cycle time, man power, and value-added ratio. Limitations of this research were also discussed, including that this research only focused on women's woven bottom products only on the production workflow. Kata Kunci: Agile System, Enhance Productivity, Garment Manufacturing, Lean Manufacturing, Value Stream Mapping.

Penerapan Lean Manufacturing Menggunakan Value Stream Mapping pada VCT Rotor di PT. XYZ

XYZ is an automotive component manufacturing company with two lines of production: the Shock Absorber Line and the VCT Line. One of the products on the VCT Line is the VCT rotor, with issues surrounding waste. Utilizing Lean Manufacturing approaches using the Waste Assessment Model and the Value Stream Analysis Tools is an effective way to solve issues and enhance efficiency in the VCT rotor system and production process at PT. XYZ. Total time savings as a result of the process change is 9,108.25 seconds, and the total lead time reduction in inventory is 34 days. The highest type of waste found in the VCT rotor is inventory, which accounts for 23,29% of the total waste. Overproduction contributes to 23,23% of the waste, while defect is responsible for 19,04%.

Application of Lean Manufacturing to Minimize Waste in The Production Process of Tin Stabilizer

Lean Manufacturing concepts were being used by the manufacturing sector more and more in an effort to maximize resource usage, cut costs, and increase efficiency. The research dived into the underlying concepts of Lean Manufacturing and its various tools and strategies for identifying and removing waste, such as overproduction, defects, needless inventory, wasteful motion, transportation, overprocessing, and waiting periods. Lean manufacturing methods could be implemented in the continuous manufacturing environment to detect and reduce waste by using a process flow chart, value stream mapping tools, waste assessment model, value stream analysis tools, and the 5 why’s method. According to the findings of the study, the most prevalent waste in the manufacturing process was waste flaws, delays, and wasteful inventory. Process activity mapping (PAM), one of VALSAT’s extensive mapping technologies, was used to eliminate waste. The lead time was reduced by 12 days and 1 hour as a consequence of the improvement recommendations study. NVA activity was reduced from 75.3% to 59.5% based on the PAM study. Reduced lead time could result in a more efficient production process and lower production costs.

LEAN SIX SIGMA APPROACH TO IMPROVE THE PRODUCTION PROCESS IN THE GARMENT COMPANY: A CASE STUDY

PT “X” is a company engaged in the garment industry. The company is facing problems that inhibit the production process. These problems comprise an excess of product defects beyond the specified limits, a considerable rate of product returns, delays in product shipment, and disorderly arrangements in storing raw material. This study aims to determine the root causes of problems in the PT “X” and provide recommendations for improvement using the concept of lean six sigma. The waste assessment model is used to identify the dominant waste, while the value stream analysis tools is a method used to analyze the causes of the dominant waste. From the research results, four dominant wastes are identified, namely waste defects, unnecessary inventory, waiting and unnecessary motion, with percentages of 27.02%, 15.92%, 14.32% and 14.0% respectively. The results of the analysis using mapping tools show the details of waste in each dominant waste. Proposed recommendations for improvement are made using the failure mode and effect analysis based on the highest risk priority number for each dominant waste. The recommendations proposed by the researchers include implementing a standard operating procedure and work instruction for the sewing process; scheduling machine maintenance using reliability centered maintenance II; planning and scheduling materials using material requirement planning; implementing line balancing; and designing name tags, visual displays, and storage rack layout.

PROPOSED IMPLEMENTATION OF LEAN MANUFACTURING TO REDUCE WASTE IN PLYWOOD PRODUCTION

CV. Treewood Abadi Group is a manufacturing company engaged in producing plywood products. In the plywood production process from raw materials to finished products there are still obstacles in the form of activities that do not have added value or waste that cause decreased efficiency and effectiveness of production activities. This study aims to identify the correlation relationship between the type of waste and waste that has the greatest effect on the plywood production process. The steps of this research are mapping the flow of the production process using waste assessment model, selection of mapping tools with value stream analysis tools and then providing proposed improvements based on the failure mode that has the highest risk priority number value. with failure mode and effect analysis, it is found that the proposed improvements are in the form of implementing visual displays, improving material handling tools, re-layout and increasing the number of workers.

Analisis Value Stream Mapping (VSM) untuk Mengeliminasi Pemborosan pada Produksi Plywood

This research aims to improve the identification of issues in plywood production at CV. Karya Purabaya. The inefficient production process leads to production times not meeting the standards, causing the company to often fail to fulfill orders on time. To implement improvements, the company needs to examine the production system comprehensively to pinpoint the issues in the production process. Value Stream Mapping (VSM) analysis, which is one of the Lean Manufacturing methods, is used to identify wasteful practices in the plywood production system. In identifying wasteful practices, Value Stream Analysis Tools (VALSAT) is utilized to identify connections and relationships between different wasteful practices. Waste Assessment Questionnaire (WAQ) is used to identify the most dominant waste, and Fishbone Diagram is employed to determine the root causes of the waste. Based on the results from the WAQ calculations, it was found that the most dominant waste is Overproduction with a percentage of 22.43%, followed by Inventory with a percentage of 20.40%. Furthermore, the WRM calculations reveal that inappropriate processing has a high percentage of 20.3%, and the value to Inventory has the highest percentage of 21.0%. The proposed improvements to minimize the most dominant waste at CV. Karya Purabaya include balancing the production process flow by implementing line balancing with an efficiency rate of 73,85%, conducting regular machine maintenance, making accurate planning and forecasting, and reducing defect.

Implementasi Lean Manufacturing Untuk Mengurangi Waste Pada Proses Produksi Sirup Markisa

Improving the quality of the production process is something that is needed by an industry. However, this will not happen if there is still waste in the production process. With a lean manufacturing strategy, companies are able to identify the types of waste that occur in the production process so that the waste that occurs can be eliminated. Waste is identified with seven wastes using the Waste Assessment Model (WAM), then detailed mapping is carried out with Value Stream Analysis Tools (VALSAT) and the root cause of the problem is analyzed with Fishbone. The results showed that the waste in the production process was a waste defect of 16.49%, the second rank was waste transportation of 16.36%, and the third rank was waste process of 14.82%. After the Fishbone analysis was carried out, we obtained suggestions for improvements to each waste which could reduce waste in the production process, from the normal time of 484 minutes for one production process to be reduced by 69 minutes

A Analysis of Factors Affecting Waste Using Value Stream Mapping (VSM) On Kaosbekas.Id

Abstract: Lean manufacturing approach is a systematic approach which identifies and eliminates waste through continuous improvement: the flow of products that customers want to pursue the perfection. This study aims to determine the amount of waste in Kaosbebas.id and examine the causes of the waste by using Value Stream Mapping (VSM), value stream analysis tools, and fish-bone diagrams. At the beginning of the study, the description of the current state map was carried out for the analysis of the fulfillment of the physical flow and the flow of information on the production of Kaosbebas.id. After weighting the waste, the researchers distributed questionnaires to informants related to the custom T-shirt production process to obtain the results of identifying the locations of waste and what things made the waste occur during the production process. Furthermore, the researchers conducted an evaluation process so that this waste reduction is expected to increase production efficiency and improve company performance. In addition, this study also aims to provide suggestions for improvements to the manufacture of custom t-shirts during the production process. This study uses a qualitative approach with the methods of observation, interviews, and questionnaires.

Eliminasi Waste Pada Proses Produksi Malt Powder Dengan Metode VSM dan VALSAT (Studi Kasus PT. XYZ)

The background of this research is that there is still waste in the malt powder production process, as evidenced by the results of the questionnaire which show 17% waste defect, 16% inventory and 15% waiting. This study aims to identify waste in the malt powder production process using a lean manufacturing approach and the tools used in this study are value stream mapping (VSM) and value stream analysis tools (VALSAT) . The initial stage is to create a value stream mapping curent state, then analysis using process activity mapping (PAM) to identify types of activities such as value added (VA), non value added (NVA) and necesary non value added. From the analysis, the value added ratio is 55.44%. Then perform waste analysis with supply chain response matrix (SCRM) and then analyze waste with quality filter mapping (QFM) for defect types of waste. The percentage of delay activity was 7.09%, where this activity was included in non-added value (NVA) activities and the results of the SCRM analysis of the raw material storage area were 1, 03, the production process area was 0.13 and the finished goods storage area was 0.96. Then the time to fulfill the order fulfillment of malt powder is 47 days with the cumulative physical stock days of 2.1 days. Keywords : Lean Manufacture , Value Stream Mapping , Value Stream Analys Tools , Process Activity Mapping, Lean Production

Integration of Lean Manufacturing and Promodel Simulation on Repair Production Process Flow of Polysilane Bottle Printing Using VSM, WAM, VALSAT, And RCA Methods: Case Study Packaging Manufacturing Company

In the production process, waste is found, which causes a decrease in the efficiency and effectiveness of the production process. The obstacle faced is not achieving the monthly production target from the target set by the company. This study aims to minimize waste or activities that do not provide added value by visualizing the ProModel simulation. The first step of the research is to identify the production process and waste using Operation Process Chart (OPC), Value Stream Mapping (VSM), and Waste Assessment Model (WAM). Based on WAM, it is known that there are 3 critical wastes, namely Transportation 13.5%, motion 13.01%, and waiting for 10.7%. Next is waste mapping with Value Stream Analysis Tools (VALSAT) using Process Activity Mapping (PAM). Based on PAM, it is known that there are 9 Value Added (VA) operations for 210 seconds and 4 Necessary but Non-Value Added (NNVA) transportation activities for 194 seconds. Then the root cause analysis was carried out using the 5 Whys Root Cause Analysis (RCA) and analysis of the design recommendations for improvement using the RCA 5W 1H tool. Based on the 5W 1H tool, it is known that there are 2 recommended improvement activities. That is by combining the machining process and changing the layout of the machine to eliminate waste. The last is the simulation of the repair results using the Promodel software. Based on the Promodel simulation with a runtime of 1440 minutes, it is known that 2,621 pcs of polysilane finish good bottles exit.

Improving the Quality of Indihome Complaints Service Using Lean Service Method (Case Study of Customer Care Plasa Telkom Solo)

PT. Telkom Indonesia is a company engaged in the telecommunications sector. Nowadays, the necessity for internet networks has increased, notably since the COVID-19 pandemic. Thus, PT. Telkom Indonesia as the largest telecommunications company in Indonesia need to improve the quality of service, especially in the Indihome complaint service process. The Indihome service complaint process often causes many queues so that customers have to wait a long time to be served. This study uses the Lean Service method, by identifying 7 wastes in service companies and then reducing the amount of waste that occurs which causes inefficient and effective service processes. This study also uses VALSAT (Value Stream Analysis Tools) to identify waste in the service system flow. In the Indihome complaint service process, there are the most critical waste, namely the waste of delays and the waste of under-utilized resources. The proposed improvements for waste of delays and waste of under-utilized resources are maximizing the use of VIRSA (Virtual Plasa) machines, educating customers to use MyIndihome application, and conducting regular training for CSR employees. Through value stream mapping current state, it is known that the total time for customers to get service is 1709 seconds and through value stream mapping future state, it is known that the total time for customers to get service is 1468 seconds for each customer.

ANALISIS WASTE MENGGUNAKAN METODE VALUE STREAM ANALYSIS TOOLS PADA PROYEK PEMBANGUNAN INSTALASI GAWAT DARURAT RSUD PIDIE JAYA

Construction project is a long process activity where the researcher finds obstacles which cannot be separated from the used resources. Everything in the projects which may add the needed costs called by the term waste. In the project implementation of Regional Public Hospital (IGD) construction project in Pidie Jaya, there was a significant delay in the project schedule which could be caused by several things which may lead the project into waste construction. This is the main reason why does the Value stream analysis tools (VALSAT) method was used during the research in order to identify the cause of occuring waste. This goal of this research is to identify the waste which potentially occure during the Regional Public Hospital (IGD) project in Pidie Jaya. Besides, this research is also determine the grade and tool waste by using the VALSAT. Based on the literature review, there are 8 wate categories which could be reviewed based on materials, labor and tools used during the project. The identified waste data are obtained by the interview conducted to 4 respondents and questionaire with 15 respondents and handed out to contratctors. Based on the result and data processing which using descriptive analysis, it can be concluded that the most influential waste on the project was waste waiting and waste overprocessing which obtain a value of 5 and cause the excessive effects on the project. Furthermore, the result of the grade analysis and tool waste determination by using the VALSAT method produced a process Acivity Mapping to analyze the occuring waste that occurs with a total score of 135.

Lean Analysis Framework for Waste Management: A Case of Indonesian Textile Company

This study aims to propose a lean analysis framework for waste management and to test it into the field case. The proposed framework was applied in a weaving process of a textile company in Indonesia. The seven classical Lean wastes were identified using value stream mapping (VSM). The result was then analyzed using the waste assessment model within which waste relationship matrix (WRM) and waste assessment questionnaire (WAQ) according to the answers of the head of weaving division studied. The major source of wastes was then determined utilizing the value stream analysis tool (VALSAT). In order to thoroughly examine the root cause of such dominant wastes and to propose corrective plans to minimize the waste, a fishbone diagram was used. As the main result, this study provides a lean waste analysis framework with examples to orientate managers about wastes. Particularly in our specific case, the results demonstrate that the waiting and defect become the most significant wastes that need to be treated. These findings allow a company to organize its activities and select tools or practices to optimize its efforts to create proper corrective plans in eliminating waste. In our study, the plans include periodic maintenance of weaving machines, clear division of tasks on the distribution of weft yarns, and eliminating unnecessary activities. In addition, it is mandatory to ensure the quality of warp yarns delivered to the weaving process as well as to perform a periodic calibration of equipment on weaving machines. This study advances in the theoretical and practical field by showing a structured way to incorporate lean analysis that can be adopted for any organization.

Implementation Lean Manufacturing Method of Plywood Manufacture Company

The Plywood company in this study was able to produce 6,000m3/ year of plywood, but during 2018 and 2019 this company was only able to provide 2,905.14 m3/year and 1,120.73 m3/year. Production in 2018 and 2019 is far below the production capacity. This research will apply the lean manufacturing concept in the production process of a plywood company. This research uses value stream mapping (VSM), value stream analysis tools (VALSAT), process activity mapping (PAM), Pareto diagrams, and root cause analysis. It is found extreme categories that occur in many processes, namely processing production and inventory. The recommendations given are to reduce employees and provide adequate storage. The future state VSM shows that a change in a lead time of 68%, and the reduction of the production process is 248.18 minutes.

Analysis of Production Process in Small Business Using Value Stream Mapping Approach

This paper aims to identify waste and analyse production process activities using the Value Stream Mapping (VSM) in a small business as a case study. The waste was identified by a waste relationship matrix and waste assessment questionnaire to determine the percentage of waste that occurs. Furthermore, a detailed selection of waste mapping based on the value stream analysis tool was carried out. Based on the VSM analysis, it was found the value added activities of 59% of the total production time and 41% of other activity times (non value added). In the case study occurred the waste for the operator's work method at the station of printing and cutting station. The VSM was performed to reducing the waste. The result depicted reduction in lead time on the production floor was 1.5 hours. So, the company in the case study can eliminate the waste time in their production process activities

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

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.

Lean distribution to minimize waste of time in the stripping process at PT. Pelabuhan Indonesia IV Ambon Branch

Stripping process at PT. Port Indonesia IV (Persero) Ambon Branch plays a very important role for expeditions to receive goods from outside its area to meet market needs. However, in the process of distributing containers to stripping blocks, there is a delay in delivery thus it does not reach the target as a result of waste. Based on the data, it is identified that the total lead time of the stripping process is 3,670 minutes which has a non-value-added activity of 3,090 minutes. It is still found delay that causes the waste so that it needs improvement by minimizing the waste. The purpose of this study is to calculate the efficiency of identified wastes and the total activity of the initial time and time after improvement. Data analysis tools used lean distribution conducted by field observations, interviews, questionnaires, and documentation with data processing techniques in the form of big picture mapping, waste identification, value stream analysis tools (VALSAT), process activity mapping, fishbone diagrams, 5W+1H methods, as well as calculating the efficiency of the improvement time. The result of this study showed that there are four wastes of seven wastes identified namely waste of transportation, waste on unnecessary inventory, waste of defects, and waste of waiting time. Waste of waiting time is a critical waste with a percentage of 29.8% based on the results of questionnaires with the causative factors namely careless parking, not paying attention to stock/targets, limited places, indiscipline, and negligence. After the improvement by minimizing waste, the lead time is 1,550 minutes with a total efficiency of activities of 42%.

Synergy of Lean and Green for Improving Small-Scale Agroindustry Performance

Small Medium Enterprises (SMEs) play an important role in the economy of Indonesia. It contributed to the 21.20% of national total economy. Global competition is a challenge and an opportunity for SMEs including agroindustry sector. Therefore, it is needed for strengthening their competitiveness. In the midst of this effort, the raising concern about environment issue has increased. This research aims to determine the alternatives or options in production aspect based on lean and green for small-scale crackers industry. Sustainable Value Stream Mapping (SVSM) was applied to describe the production condition and identify wastes from lean and green point of view. Furthermore, Value Stream Analysis Tools (VALSAT) and Life Cycle Impact Assessment (LCIA) were used to analyze waste throughout the production activity. The results show that the small-scale cracker industry has already implemented synergy of lean and green, however some alternatives for reducing lead time and waste are needed such as demand forecasting and improvement of working methods