INCREASING EFFICIENCY OF SAMPLE SEARCHING ACTIVITY IN INJECTION MOLDING DEPARTMENT AT PT XYZ BY USING PDCA CYCLE

Abstract

The Injection Molding department at PT XYZ is facing issues with sample searching, which is leading to decreased productivity and increased production costs. The aim of this study, conducted using the PDCA cycle, was to identify the root causes of the issue between April and August 2022 and increase the efficiency of the sample searching activity. Objectives included reducing searching time, utilizing space more effectively, increasing sample storage capacity, and reducing potential loss costs. Action plans included adding drawers and shelves, and creating a bank database of the sample locator. As a result, searching time decreased by 91%, space utilization increased to 14%, capacity increased by 136%, and the cost of lost output was reduced by up to 91%, or Rp78,938,000.20 each month. Additionally, the cost of lost searching hours was reduced by 84%, or Rp1,798,197.00. As a result, the Injection Molding department can save up to 91% of the searching time, equivalent to Rp80,736,197.20 total cost savings each month.