Improvement recommendation to eliminate waste on the production process of line laminating door component with value stream mapping and waste assessment model method

Abstract

Through lean manufacturing approach companies can identify waste in the production line as well as the impact on production lead time. The purpose of this research is to reducing waste on the business production line by using Value Stream Mapping and Waste Assessment Model to improve the performance and capacity production company. Value Stream Mapping method is employed to show current mapping and waste condition by identifying non-value-added activity category. Moreover, Waste Assessment Model method is used to search, identify and eliminate seven wastes contained in the production line. Based on the analysis, this study proposed several recommendations which could support the production line performance, namely adding a few assembly lines and installing Hydraulic Lifter Machines; and designing a continuous flow on the production line. The evaluation results showed that the improvement recommendations could decrease the production lead time to 20,640.4 seconds, increasing cycle time to 24.07 second, and enhancing production capacity to 2244 units per day.