Production waste analysis using value stream mapping and waste assessment model in a handwritten batik industry

Abstract

Batik is one of Indonesian cultural heritage that confirmed by United Nations of Educational, Scientific, and Cultural Organization (UNESCO) on October 2009. This legal confirmation improves the number of batik industry from many regions based its local unique characteristic. The increasing number of batik SMEs in Indonesia requires a strategy that can create competitive advantage. This strategy can be done by reducing production waste. One of Indonesian batik SMEs is SME Batik CM located in Yogyakarta. There are several problems that occur in the industry, i.e. length of the production process, spots on Batik and excessive raw materials inventory. Based on that problems, this research is done by applying lean manufacturing concept using value stream mapping (VSM) method to evaluate production wastes. Based on the result of the research, there are seven types of production waste: overproduction (9,62%), inventory (17,3%), defect (23,08%), motion (9,62%), transportation (9,62%), Over processing (9,62%) and waiting (21,15%). Process improvement is done to reduce the highest waste, defect, using quality filter mapping (QFM).