VALUE STREAM MAPPING IMPLEMENTATION AND IMPROVEMENT AT PT. HW

Abstract

In facing the free market era, PT.XI is required to increase their competitiveness to produce products in effective and efficient way. As a toy manufacturing company, PT.XI tend to produce good quality of product. It can be achieved by optimize the production process. In order to achieve production process optimization, observation is done to analyze non-value added occur in company. Implementation of lean approach is use to determine unnecessary activity by conduct value stream mapping. From current stream mapping, Die Cast area contributes high number of non-value added. As the initial stage in production process of car, die cast plays an important role, since many part produced in this stage. The objectives of this research are to analyze possibility improvement in production process, to eliminate non-value added activity, and to proposed improvements in toy production system. To overcome with inventory management system, method being proposed is Economic Order Quantity (EOQ) and Vendor Managed Inventory (VMI). Whereas, according to machine reliability problem, the proposed method is Total Productive Maintenance (TPM) to increase OEE performance. As the final result, some improvements in die cast area are occur, such as inventory stacking from 19 days to 5 days, OEE performance increase from 88% to 73%. Thus, proposed improvement is considered as efficient.