Waste Analysis in the Speaker Box Assy Process to Reduce Lead Time in the Electronic Musical Instrument Industry
Abstract
Purpose: This study aims to analyse the waste in the production line to get an efficient production lead time.
Methodology/Approach: This research uses the integration method of value stream mapping and kaizen. Based on the analysis with expert judgment, it is known that the waste comes from an inefficient factory layout. Improvements by making changes to factory layouts and merging workstations.
Findings: This research has found waste caused by ineffective factory layouts based on Focus Group Discussions (FGD). Improvements by incorporating workstations and changes to the factory layout can reduce production lead time. The results showed that the production lead time decreased from 3.21 days to 2.31 days or a decrease in the ratio of 31.15%.
Research Limitation/Implication: This research can also improve manufacturing performance such as cost efficiency, efficient layout, and labour reduction. So for similar companies, this research can be a reference for making improvements in reducing waste that can improve manufacturing performance so that they can compete in national and international markets.
Originality/Value of paper: This paper provides benefits for the musical instrument industry regarding waste reduction. According to this research, lean production can increase the productivity and quality of the production system, because it can eliminate the waste of time or the production process. The new approach of this research is used the integration methods by involving experts through FGDs to make improvements and reduce waste in the production line.
References
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Stadnicka, D. and Ratnayake R.M.Ch., 2016. Minimization of of Service Service Disturbance : VSM Based Case Study in Telecommunication. IFAC-PapersOnLine, [e-journal] 49(12), pp.255-260. DOI: 10.1016/j.ifacol.2016.07.609.
Stadnicka, D. and Ratnayake, R.M.Ch., 2017. Enhancing Aircraft Maintenance Services : A VSM Based Case Study. Procedia Engineering, [e-journal] 182, pp.665-672. DOI: 10.1016/j.proeng.2017.03.177.
Suhardi, B., Putri, M.H.K.S. and Jauhari, W.A., 2020. Implementation of Value Stream Mapping to Reduce Waste in a Textile Products Industry. Cogent Engineering, [e-journal] 7(1). DOI: 10.1080/23311916.2020.1842148.
Sukma, D.I., Prabowo, H.A., Setiawan, I., Kurnia, H. and Maulana, I., 2022. Implementation of Total Productive Maintenance to Improve Overall Equipment Effectiveness of Linear Accelerator Synergy Platform Cancer Therapy. International Journal of Engineering, [e-journal] 35(7), pp.1246-1256. DOI: 10.5829/ije.2022.35.07a.04.
Tannady, H., Gunawan, E., Nurprihatin, F. and Wilujeng, F.R., 2019. Process Improvement to Reduce Waste in the Biggest Instant Noodle Manufacturing Company in South East Asia. Journal of Applied Engineering Science, [e-journal] 17(2), pp.203-212. DOI: 10.5937/jaes17-18951.
Ustyugová, T. and Noskievičová, D., 2013. Integration of Lean and Agile Manufacturing Based on Principles from Wikinomics. Quality Innovation Prosperity, [e-journal] 17(1), pp.48-56. DOI: 10.12776/qip.v17i1.63.
Zahoor, S. and Kader, W.A., 2019. A Combined VSM and Kaizen Approach for Sustainable Continuous Process Improvement. International Journal of Industrial Engineering and Operations Management (IJIEOM), [e-journal] 1(2), pp.125-137.
Baby, B., Prasanth, N. and Jebadurai1, D.S., 2018. Implementation of Lean Principles to Improve the Operations of a Sales Warehouse in the Manufacturing Industry. International Journal of Technology, [e-journal] 9(1), pp.46-54. DOI: 10.14716/ijtech.v9i1.1161.
Chowdhury, A.H., 2016. Application of Lean Tool - Value Stream Mapping (VSM). Scholars Journal of Engineering and Technology, [e-journal] 4(10), pp.482-88. DOI: 10.21276/sjet.2016.4.10.3.
Garza-Reyes, J.A., Forero, J.S.B., Kumar, V., Cedillo-Campos, M.G. and Rocha-Lona, L., 2017. Improving Road Transport Operations Using Lean Thinking. Procedia Manufacturing, [e-journal] 11, pp.1900-1907. DOI: 10.1016/j.promfg.2017.07.332.
Hasanah, F.A., Nurhudah, M., Mulyono, M. and Dillon, M., 2020. Kaizen Implementation in Seaweed Aquaculture (Gracilaria Sp.) in Karawang, West Java: A Productivity Improvement Case Study. In: IOP, IOP Conference Series: Earth and Environmental Science, Volume 414, The World Seafood Congress 2019 – "Seafood Supply Chains of the Future: Innovation, Responsibility, Sustainability". Penang, Malaysia. 9-11 September 2019. IPOScience. DOI: 10.1088/1755-1315/414/1/012007.
Haviana, E. and Hernadewita, H., 2019. Productivity Improvement in the Rubber Production Process Using Value Stream Mapping Method to Eliminate Waste. Operations Excellence: Journal of Applied Industrial Engineering, [e-journal] 11(2), pp.119-130. DOI: 10.22441/oe.v11.2.2019.023.
International Trade Centre (ITC), 2019. Trade Map - List of Exporters for the Selected Product in 2019. [List of exporters for the selected product > Pianos, Incl. Automatic > Harpsichords and Other Keyboard Stringed Instruments] [online] Trade Statistics for International Business Development. Available at: < https://www.trademap.org/Country_SelProduct.aspx? > [Accessed 18 October 2020].
Kurnia, H. and Purba, H.H., 2021. A Systematic Literature Review of Lean Six Sigma in Various Industries. Journal of Engineering and Management in Industrial System, [e-journal] 9(2), pp.19-30. DOI: 10.21776/ub.jemis.2021.009.002.3.
Kurnia, H., Jaqin, Ch. and Purba, H.H., 2022. The PDCA Approach with OEE Methods for Increasing Productivity in the Garment Industry. Jurnal Ilmiah Teknik Industri: Jurnal Keilmuan Teknik Dan Manajemen Industri, [e-journal] 10(1), pp.57-68. DOI: 10.24912/jitiuntar.v10i1.15430.
Kurnia, H., Jaqin, Ch., Purba, H.H. and Setiawan, I., 2021. Implementation of Six Sigma in the DMAIC Approach for Quality Improvement in the Knitting Socks Industry. Tekstil Ve Muhendis, [e-journal] 28(124), pp.269-278. DOI: 10.7216/1300759920212812403.
Nandakumar, N., Saleeshya, P.G. and Harikumar, P., 2020. Bottleneck Identification and Process Improvement by Lean Six Sigma DMAIC Methodology. Materials Today: Proceedings, [e-journal] 24(2), pp.1217-1224. DOI: 10.1016/j.matpr.2020.04.436.
Pech, M. and Vaněček, D., 2018. Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity, [e-journal] 22(2), pp.1-15. DOI: 10.12776/qip.v22i2.1096.
Prayugo, J. and Zhong, L.X., 2021. Green Productivity : Waste Reduction with Green Value Stream Mapping. A Case Study of Leather Production. International Journal of Production Management and Engineering, [e-journal] 9(1), pp.47-55. DOI: 10.4995/ijpme.2021.12254.
Purba, H.H., Fitra, A. and Nindiani, A., 2019. Control and Integration of Milk-Run Operation in Japanese Automotive Company in Indonesia. Management and Production Engineering Review, [e-journal] 10(1), pp.79-88. DOI: 10.24425/mper.2019.128246.
Romero, L.F. and Arce, A., 2017. Applying Value Stream Mapping in Manufacturing: A Systematic Literature Review. IFAC-PapersOnLine, [e-journal] 50(1), pp.1075-1086. DOI: 10.1016/j.ifacol.2017.08.385.
Rother, M. and Shook, J., 2003. Learning to See: Value Stream Mapping to Add Value and Eliminate Muda. Cambridge: Lean Enterprise Institute, Inc.
Santosa, W.A. and Sugarindra, M., 2018. Implementation of Lean Manufacturing to Reduce Waste in Production Line with Value Stream Mapping Approach and Kaizen in Division Sanding Upright Piano, Case Study in PT. X. MATEC Web of Conferences, [e-journal] 154(1), pp.8-11. DOI: 10.1051/matecconf/201815401095.
Setiawan, I. and Hernadewita, H., 2022. Reducing Production Process Lead Time Using Value Stream Mapping and Kaizen Approaches : A Case Study in the Musical Instrument Industry. AIP Conference Proceedings, [e-journal] 2470(1), 020005. DOI: 10.1063/5.0080159.
Setiawan, I., Tumanggor, O. and Purba, H.H., 2021. Value Stream Mapping: Literature Review and Implications for Service Industry. Jurnal Sistem Teknik Industri, [e-journal] 23(2), pp.155-166. DOI: 10.32734/jsti.v23i2.6038.
Setiawan, S., Setiawan, I., Jaqin, Ch., Prabowo, H.A. and Purba, H.H., 2021. Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry. Quality Innovation Prosperity, [e-journal] 25(3), pp.48-64. DOI: 10.12776/qip.v25i3.1613.
Silva, R.S., De Alencar, D.B., Costa, A.P.T. and Sanches, A.E., 2019. Kaizen Philosophy Application as Production Standardization and Process Optimization. International Journal for Innovation Education and Research, [e-journal] 7(11), pp.808-816. DOI: 10.31686/ijier.vol7.iss11.1936.
Siregar, K., Ariani, F. and Tambunan, M.M., 2019. Reducing Waste in Spare Part Production Process with Lean Manufacturing Approach. IOP Conference Series: Materials Science and Engineering, [e-journal] 648, pp.1-8. DOI: 10.1088/1757-899X/648/1/012016.
Stadnicka, D. and Ratnayake R.M.Ch., 2016. Minimization of of Service Service Disturbance : VSM Based Case Study in Telecommunication. IFAC-PapersOnLine, [e-journal] 49(12), pp.255-260. DOI: 10.1016/j.ifacol.2016.07.609.
Stadnicka, D. and Ratnayake, R.M.Ch., 2017. Enhancing Aircraft Maintenance Services : A VSM Based Case Study. Procedia Engineering, [e-journal] 182, pp.665-672. DOI: 10.1016/j.proeng.2017.03.177.
Suhardi, B., Putri, M.H.K.S. and Jauhari, W.A., 2020. Implementation of Value Stream Mapping to Reduce Waste in a Textile Products Industry. Cogent Engineering, [e-journal] 7(1). DOI: 10.1080/23311916.2020.1842148.
Sukma, D.I., Prabowo, H.A., Setiawan, I., Kurnia, H. and Maulana, I., 2022. Implementation of Total Productive Maintenance to Improve Overall Equipment Effectiveness of Linear Accelerator Synergy Platform Cancer Therapy. International Journal of Engineering, [e-journal] 35(7), pp.1246-1256. DOI: 10.5829/ije.2022.35.07a.04.
Tannady, H., Gunawan, E., Nurprihatin, F. and Wilujeng, F.R., 2019. Process Improvement to Reduce Waste in the Biggest Instant Noodle Manufacturing Company in South East Asia. Journal of Applied Engineering Science, [e-journal] 17(2), pp.203-212. DOI: 10.5937/jaes17-18951.
Ustyugová, T. and Noskievičová, D., 2013. Integration of Lean and Agile Manufacturing Based on Principles from Wikinomics. Quality Innovation Prosperity, [e-journal] 17(1), pp.48-56. DOI: 10.12776/qip.v17i1.63.
Zahoor, S. and Kader, W.A., 2019. A Combined VSM and Kaizen Approach for Sustainable Continuous Process Improvement. International Journal of Industrial Engineering and Operations Management (IJIEOM), [e-journal] 1(2), pp.125-137.
Authors
Aprianto, T., Nuryono, A., Setiawan, I., Kurnia, H., & Purba, H. H. (2022). Waste Analysis in the Speaker Box Assy Process to Reduce Lead Time in the Electronic Musical Instrument Industry. Quality Innovation Prosperity, 26(3), 53–65. https://doi.org/10.12776/qip.v26i3.1744
This work is licensed under a Creative Commons Attribution 4.0 International License.