LEAN MANUFACTURING IMPLEMENTATION TO REDUCE REJECTION RATE OF CRANKCASE

Abstract

Lean is the goal for each company in today’s competitive business environment. Yet achieving lean manufacturing itself would need some times with the cooperative performance from overall employees who works there. It is valid for PT. XYZ as one of the biggest motorcycles manufacturing company in Indonesia producing many types of motorcycles and supported by three main plants resulted in total production of 35 million units on 2012. High reject rate is one of the problems that cause the company cannot achieve lean manufacturing. It is currently occur in die-casting area in PT.XYZ. By implementing lean manufacturing method, the waste produced such as reject rate can be defined carefully after conducted the lean manufacturing assessment and the part that has the highest reject rate is then found. The problem can be analyzed by using simple analytical tool such as check sheet and Pareto analysis, continued by doing some brainstorming to find the root cause as to be solved later. At the end of the research, the average reject rate is reduced by 1.21% after taking the corrective actions and it is given the recommendation for further company’s planning.