| Problems that are occurred in PT. Jayatama Selaras during the preliminary research are caused by wastes. Current state value stream mapping with Hot in Cream bottle as line model is mapped to find out wastes that have not been found. Wastes found on the production floor are overproduction, overprocessing, excess inventory, and excess conveyance. The 5Whys method is used to determine the root cause of each wastes. The improvement with lean manufacturing system approach will be recommended through four stages: general stage, demand stage, flow stage, and leveling stage. In the general stage, 5S method will be proposed to eliminate excess conveyance and as a basis for implementing lean manufacturing system. Takt time and pitch is determined on the demand stage to find out daily production requirements. In the flow stage, autonomous maintenance and Kanban proposed so that waste overprocessing and excess inventory can be resolved, in-process supermarkets and the runner also proposed for Kanban method. In the levelling stage, heijunka box will be proposed for some production lines so that it can control WIP according to pitch time. The future state value stream mapping is mapped to determine the ideal conditions that can occur if the proposed improvements are applied. The result, PCE increased dramatically, the PCE calculation from current state is only 1.9%, on the other hand, PCE from future state is increased to 12.4%. |