This thesis describes about the recommendation of lean manufacturing system for minimizing waste. The study case takes place at PT. Intercallin. PT. Intercallin is a company which product is dry-cell battery. Overall explanation of the production system is explained using the current
state value stream mapping. Based on the calculation, it is known that the Process Cycle Efficiency (PCE) of current condition only at 6,52%. The Overall Equipment Effectiveness (OEE) for the current condition is 79.11%, which consist of 85,71% availability, 92.8% performance, and 99.47% quality. Observation results in the shop floor show that there’s still waste founded. Based on the waste identification checklists, seven kinds of waste are identified. Root cause analysis informs that the root causes of the waste are uncalculated takt time, usage push system, and changing demand of the customer. Based on the root cause analysis, this thesis recommends the lean manufacturing system to eliminate the root cause and prevent it for reoccur. The recommendation includes the 5S, line balancing, kanban, heijunka, and work standard. Overall view of the recommendation can be seen on the future state value
stream mapping. The recommendation supposed to increase the PCE to 10.86% and OEE to 80.77%. Although this system can’t be classified as lean, but this condition has minimize the waste on the shop floor. |