INCREASING OUTPUT OF TRUCK 2528C AND 2528R PRODUCTION IN PT. XYZ

Abstract

PT XYZ is the automotive company that produces the trucks type of 2528 C and 2528 R which are sold domestically and abroad. Since the demand of truck in PT XYZ are increasingly than the previous year, and the cycle time is still high. The cycle time of current system is 667.97 minutes. The cycle time is high because some activities is categorized as waste. Even the Value-Added activity is in good percentage but some activities need to be decreased or removed. In this study, the lean manufacturing method used is the Value Stream Mapping (VSM) method, to facilitate the waste identification process using the Process Activity Mapping (PAM) method. Waste that has been identified is grouped according to the sevenwaste category. The waste that inhibit the truck production line are motion and transportation. After the wastes production are define, then the proposed improvement is used through many ways such as changing the facility layout, line balancing, standardized work, and 5s principle. Then, the cycle time are decreasing from 667.97 minutes to 501.72 minutes. The balancing rate is also change from 65.54 % to 75 %. The target outputS are increasing from 5 trucks/day to 6 trucks/day.