Integration of Lean Manufacturing and Promodel Simulation on Repair Production Process Flow of Polysilane Bottle Printing Using VSM, WAM, VALSAT, And RCA Methods: Case Study Packaging Manufacturing Company

Abstract

In the production process, waste is found, which causes a decrease in the efficiency and effectiveness of the production process. The obstacle faced is not achieving the monthly production target from the target set by the company. This study aims to minimize waste or activities that do not provide added value by visualizing the ProModel simulation. The first step of the research is to identify the production process and waste using Operation Process Chart (OPC), Value Stream Mapping (VSM), and Waste Assessment Model (WAM). Based on WAM, it is known that there are 3 critical wastes, namely Transportation 13.5%, motion 13.01%, and waiting for 10.7%. Next is waste mapping with Value Stream Analysis Tools (VALSAT) using Process Activity Mapping (PAM). Based on PAM, it is known that there are 9 Value Added (VA) operations for 210 seconds and 4 Necessary but Non-Value Added (NNVA) transportation activities for 194 seconds. Then the root cause analysis was carried out using the 5 Whys Root Cause Analysis (RCA) and analysis of the design recommendations for improvement using the RCA 5W 1H tool. Based on the 5W 1H tool, it is known that there are 2 recommended improvement activities. That is by combining the machining process and changing the layout of the machine to eliminate waste. The last is the simulation of the repair results using the Promodel software. Based on the Promodel simulation with a runtime of 1440 minutes, it is known that 2,621 pcs of polysilane finish good bottles exit.