Implementation of Lean Manufacturing to Reduce Waste in the Maintenance Section in National Automotive Sub Companies of Indonesia
Keywords:Waste, Rate of Quality, Overall Equipment Effectiveness, DMAIC
Diamond Motorindo is a company that produces four-wheeled vehicles, one of which is a Multi-Purpose Vehicle (MPV) type. In the MPV manufacturing process, the quality problem that is currently a trend is the AC Not Fill defect. Based on company data for the period March 2019 ~ February 2020, the defect continues to increase. The defect occurred due to the failure of filling the AC gas into the vehicle by the AC Filling Machine. This study aims to determine the OEE value of the AC filling machine is, the factors that cause machine failure that causes defects and can obtain improvement efforts to improve quality. The steps taken in this study are first to calculate the respective values of availability, performance, and rate of quality from the AC Filling Machine to find which variable has the lowest value with the OEE method. After obtaining the variable with the lowest value, the next step is to solve the problem of low variables by using the DMAIC method. After analyzing it, it can be concluded that the average OEE AC Filling Machine value during March 2019 ~ February 2020 is around 96%. This value is still below the target set by the company, which is 98%. What prevents the OEE value target from being achieved is the machine's low rate of quality. The contributing factors are humans, methods, machines/tools, and materials.
Chiarini, A. (2015). Improvement of OEE performance using a Lean Six Sigma approach: An Italian manufacturing case study int. J. Productivity and Quality Management, 16(4), 416–433. https://doi.org/10.1504/IJPQM.2015.072414
Gaspersz, V. (2005). Total Quality Management. Publisher PT. Gramedia Pustaka Utama, Jakarta.
Ginting, R. (2007). Product Design. Graha Ilmu.
Hervian, M. S., & Soekardi, C. (2016). Improving Productivity Based on Evaluation Score of Overall Equipment Effectiveness (OEE) Using DMAIC Approach on Blistering Machine. International Journal of Science and Research (IJSR), 5(7), 736–739. https://doi.org/10.21275/v5i7.ART2016204
Kholil, M., Hendri, & Hanum, B. (2018). Quality assessment of nylon filament yarn product using DMAIC method and Failure Mode and Effect Analysis (FMEA) method (case study: PT.ITS). Proceedings of the International Conference on Industrial Engineering and Operations Management.
Kholil, M., Maulidina, A. D., & Rimawan, E. (2016). Analysis of Total Productive Maintenance on Ship/Fleet Productivity Using Overall Equipment Effectiveness Method at PT. Global Trans Energy International. Journal of Industrial Engineering & Management Systems, 9(1), 1–18. https://doi.org/10.30813/JIEMS.V9I1.125
Kholil, M., & Pambudi, T. (2010). Implementation of Lean Six Sigma in Quality Improvement By Reducing Defective Products Ng Drop In The Hl 4.8 Product Final Test Machine At Pt. Sis. PASTI Journal, VIII(1), 14–29.
Nasution, A. H., & Prasetiyawan, Y. (2008). Production planning and control. Graha Ilmu.
Kholil, M., Haekal, J., Eko Adi Prasetio, D., & Sulaiman Hasan. 2020. The Lean Manufacturing Design For Improving Production Scheduling Using Product Wheel Method in Chemical Manufacturing Company, Indonesia. International Journal of Engineering Research and Advanced Technology - IJERAT (ISSN: 2454-6135), 6(8), 12-18.
Haekal, J., & Setio, H. 2017. Selection of Raw Material Suppliers Using Analytical Hierarchy Process in Food and Beverage Company, South Jakarta. ComTech: Computer, Mathematics and Engineering Applications, 8(2), 63-68.
HAEKAL, J. (2018). PERANCANGAN DAN EVALUASI IMPLEMENTASI SISTEM MANAJEMEN MUTU ISO 9001: 2015 MELALUI KEPUASAN PELANGGAN DI UNIVERSITAS ISLAM AS-SYAFI’IYAH (Doctoral dissertation, Universitas Mercu Buana Jakarta).
Kholil, M., Haekal, J. H, Sulaiman. 2020. Lean Manufacturing Design to Reduce Waste in Gear Production Process Using VSM and Kaizen Method Approaches (Case Study: Gear Primary Driven K56 Product). Journal of Scientific and Engineering Research. 7(8), 1-9
Haekal, J., & Prasetio, D. E. A. Planning Of Production Facilities Layouts In Home Industry With The Systematic Layout Planning Method.
haekal, J., & Setiawan, I. (2020). Comparative Analysis of Raw Materials Control Using JIT and EOQ method For Cost Efficiency of Raw Material Supply in Automotive Components Company Bekasi, Indonesia. International Journal of Engineering Research and Advanced Technology (ijerat), 6(10), 76-82. https://doi.org/10.31695/IJERAT.2020.3661
Ng, K. C., Chong, K. E., & Goh, G. G. G. (2014). Improving Overall Equipment Effectiveness (OEE) through the six sigma methodology in a semiconductor firm: A case study. IEEE International Conference on Industrial Engineering and Engineering Management. https://doi.org/10.1109/IEEM.2014.7058755
Nurprihatin, F., Jodiawan, P., Fernando, N., & Gurusinga, G. K.-K. (2017). Usulan Perbaikan Performa Mesin Toelasting Glue dengan Integrasi OEE dan Metode DMAIC (Studi Kasus: Perusahaan Manufaktur Sepatu). Prosiding Seminar Nasional Teknologi Dan Informatika ISBN:978-602-1180-50-1, 725–732.
Pereira, A. M. H., Silva, M. R., Domingues, M. A. G., & Sá, J. C. (2020). Lean six sigma approach to improving the production process in the mold industry: A case study. Quality Innovation Prosperity, ISSN 1335-1745 (Print) ISSN 1338-984X, 23(9), 103–121. https://doi.org/10.12776/QIP.V23I3.1334
How to Cite
Copyright (c) 2021 Indra Almahdy, Muhammad Kholil, Jakfat Haekal, Arie Firmansyah, Dede Rukmayadi
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.