Implement the Lean Manufacturing approach

Oct 13, 2025 by talynt.org 3 views

Design to Improve the Main Shaft Production Process with Lean Manufacturing to Increase Productivity at PT Apindowaja Effective Persada

Introduction

The oil palm processing machine parts industry in North Sumatra has experienced significant development in recent years. PT Apindowaja Effective Persada, one of the main actors in this industry, produces various important components such as Main Shaft, Cone, Intermediate Gear, Protect Nut, Pulley, Flexible Couple, Press Cage, Screw Press, and Digester. However, this company faces serious challenges in the main shaft production process, where delays in completion of orders often occur. This delay not only has an impact on the company's financial conditions but also in the partnership relations that have been built. Low productivity in terms of utilization of resources is one of the main causes of this problem.

The Need for Improvement

In an effort to increase productivity, this study aims to design an efficient improvement of production processes with a focus on identification and elimination of activities that do not provide added value (non-value added activity). One effective method to achieve this goal is to apply the principle of lean manufacturing. The lean manufacturing approach serves to reduce and eliminate activities that do not make a positive contribution to the production process. In this study, the emphasis was given to the identification of non-value added activity using the value stream mapping technique and the application of the pull demand system to achieve the optimal production process efficiency.

Analysis of the Current State

Based on the analysis conducted, it was found that the Process Cycle Efficiency (PCE) value was 11.89%, which showed a significant increase in potential. In addition, process velocity also reflects the performance of the process that needs to be improved. From the entire main shaft production process, 9,509.51 minutes identified is a non-value added activity of the total time which reached 10,804.59 minutes. This indicates a waste that must be overcome immediately.

Value Stream Mapping

Value stream mapping is a technique used to identify and visualize the flow of materials and information through a production process. It helps to identify areas of waste and opportunities for improvement. In this study, the value stream mapping process was used to identify the non-value added activities in the main shaft production process. The results of the value stream mapping process showed that the total lead time can be reduced to 6,449.51 minutes, which will certainly have a positive effect on increasing productivity.

Application of the Pull Demand System

The pull demand system is a production planning and control system that uses a Kanban card to signal the need for production. It is a key component of the lean manufacturing approach. In this study, the application of the pull demand system with Kanban card aids was proposed as a measure of improvement. This proposed improvement is expected to reduce the total lead time from 10,804.59 minutes to be more efficient, with an estimated reduction of 4,355.08 minutes on the Future State Map.

Benefits of the Proposed Improvement

With the application of the Lean Manufacturing method and focus on reducing waste, PT Apindowaja Ampuh Persada has the opportunity to improve its operational efficiency. This will not only accelerate the settlement of orders, but also strengthen the company's position in a competitive market. Thus, this approach not only provides financial benefits, but also strengthens relationships with business partners, which in turn can bring the company to greater success in the future.

Conclusion

In conclusion, this study aims to design an efficient improvement of production processes with a focus on identification and elimination of activities that do not provide added value (non-value added activity). The application of the lean manufacturing approach and the value stream mapping technique has shown that the total lead time can be reduced to 6,449.51 minutes, which will certainly have a positive effect on increasing productivity. The proposed improvement is expected to reduce the total lead time from 10,804.59 minutes to be more efficient, with an estimated reduction of 4,355.08 minutes on the Future State Map. This approach not only provides financial benefits, but also strengthens relationships with business partners, which in turn can bring the company to greater success in the future.

Recommendations

Based on the findings of this study, the following recommendations are made:

Implement the Lean Manufacturing approach: The lean manufacturing approach should be implemented in the main shaft production process to reduce waste and improve productivity.
Use Value Stream Mapping: Value stream mapping should be used to identify and visualize the flow of materials and information through the production process.
Apply the Pull Demand System: The pull demand system with Kanban card aids should be applied to signal the need for production and to reduce the total lead time.
Monitor and Evaluate: The proposed improvement should be monitored and evaluated regularly to ensure that the expected benefits are achieved.

Future Research Directions

This study has shown that the application of the lean manufacturing approach and the value stream mapping technique can improve productivity in the main shaft production process. However, there are still many areas that need to be explored in future research. Some potential areas for future research include:

Implementation of the Lean Manufacturing approach in other production processes: The lean manufacturing approach should be implemented in other production processes to reduce waste and improve productivity.
Development of a more comprehensive value stream mapping technique: A more comprehensive value stream mapping technique should be developed to identify and visualize the flow of materials and information through the production process.
Evaluation of the effectiveness of the pull demand system: The effectiveness of the pull demand system should be evaluated to ensure that it is meeting its intended purpose.

Limitations of the Study

This study has some limitations that should be noted. Some of the limitations include:

Limited scope: The study was limited to the main shaft production process and did not consider other production processes.
Limited data: The study was based on limited data and did not consider other factors that may affect productivity.
Limited time frame: The study was conducted over a limited time frame and did not consider long-term effects.

Conclusion

In conclusion, this study has shown that the application of the lean manufacturing approach and the value stream mapping technique can improve productivity in the main shaft production process. The proposed improvement is expected to reduce the total lead time from 10,804.59 minutes to be more efficient, with an estimated reduction of 4,355.08 minutes on the Future State Map. This approach not only provides financial benefits, but also strengthens relationships with business partners, which in turn can bring the company to greater success in the future.
Q&A: Design to Improve the Main Shaft Production Process with Lean Manufacturing to Increase Productivity at PT Apindowaja Effective Persada

Q: What is the main problem faced by PT Apindowaja Effective Persada in the main shaft production process?

A: The main problem faced by PT Apindowaja Effective Persada in the main shaft production process is the delay in completion of orders, which has an impact on the company's financial conditions and partnership relations.

Q: What is lean manufacturing, and how can it help improve productivity in the main shaft production process?

A: Lean manufacturing is a production approach that aims to minimize waste and maximize value-added activities. By applying lean manufacturing principles, PT Apindowaja Effective Persada can reduce waste, improve efficiency, and increase productivity in the main shaft production process.

Q: What is value stream mapping, and how can it help identify areas for improvement in the main shaft production process?

A: Value stream mapping is a technique used to identify and visualize the flow of materials and information through a production process. By using value stream mapping, PT Apindowaja Effective Persada can identify areas of waste and opportunities for improvement in the main shaft production process.

Q: What is the pull demand system, and how can it help reduce the total lead time in the main shaft production process?

A: The pull demand system is a production planning and control system that uses a Kanban card to signal the need for production. By applying the pull demand system, PT Apindowaja Effective Persada can reduce the total lead time in the main shaft production process and improve productivity.

Q: What are the expected benefits of implementing the lean manufacturing approach and the value stream mapping technique in the main shaft production process?

A: The expected benefits of implementing the lean manufacturing approach and the value stream mapping technique in the main shaft production process include:

Reduced waste and improved efficiency
Increased productivity and reduced lead time
Improved quality and reduced defects
Enhanced customer satisfaction and loyalty
Increased competitiveness and market share

Q: What are the limitations of this study, and how can they be addressed in future research?

A: The limitations of this study include:

Limited scope: The study was limited to the main shaft production process and did not consider other production processes.
Limited data: The study was based on limited data and did not consider other factors that may affect productivity.
Limited time frame: The study was conducted over a limited time frame and did not consider long-term effects.

To address these limitations, future research can focus on:

Implementing the lean manufacturing approach in other production processes
Developing a more comprehensive value stream mapping technique
Evaluating the effectiveness of the pull demand system
Considering other factors that may affect productivity

Q: What are the next steps for PT Apindowaja Effective Persada to implement the lean manufacturing approach and the value stream mapping technique in the main shaft production process?

A: The next steps for PT Apindowaja Effective Persada to implement the lean manufacturing approach and the value stream mapping technique in the main shaft production process include:

Conducting a thorough analysis of the current state of the main shaft production process
Identifying areas for improvement and developing a plan to address them
Implementing the lean manufacturing approach and the value stream mapping technique
Monitoring and evaluating the effectiveness of the changes
Continuously improving and refining the process to achieve optimal results.

Q: How can other companies benefit from the findings of this study?

A: Other companies can benefit from the findings of this study by:

Implementing the lean manufacturing approach and the value stream mapping technique in their own production processes
Conducting a thorough analysis of their current state and identifying areas for improvement
Developing a plan to address areas for improvement and implementing changes
Monitoring and evaluating the effectiveness of the changes
Continuously improving and refining their processes to achieve optimal results.

By following these steps, other companies can also improve their productivity, efficiency, and competitiveness, and achieve better results in their own production processes.