Implementation of Lean Six Sigma Framework in Production Process of Sheet Press Forming for Aerospace Industry

• Main Author: Lidyana 29116001, Prilla
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/29979
• Institution: Institut Teknologi Bandung

Indonesian Aerospace is a genuine state-owned aerospace company in Indonesia which designs and manufactures both civilian and military regional commuter aircraft. Indonesian Aerospace has four core business, which include Aircraft Development, Aero Structure, Aircraft Services, Technology and Development. Indonesian Aerospace as an aircraft manufacturer has applied Lean Manufacturing in its production process on shop floor. Unfortunately, like any other companies that have issues in operation management, utilisation of Lean Manufacturing tools in Indonesian Aerospace has not been effectively applied. <br /> <br /> Based on the routing table and the performance (KPIs) on shop floor, specifically at sheet press forming area, there are some problems found in the processes that lead to slow and inefficient cycle time of production. According to the KPIs numbers, there are some problems happen in delivery process as it shows that the objectives in On Time Delivery (OTD) in some months had not been achieved. <br /> <br /> Lean Six Sigma uses systematic framework called DMAIC (Define, Measure, Analyse, Improve, and Control) cycle for mapping and solving the problem found in production process. During define phase, the author identified the opportunity for improvement and defined the process by mapping the process at sheet press forming area through value stream mapping. In measure phase, the data of shop floor performance (KPIs) were collected. The root causes of the problems were identified during analyse phase using Five Whys. There were no comprehensive and effective SOP (Standard Operating Procedure) on shop floor and lack of employee engagement. The recommendation in improve phase is to form more organized working habit and requirement by developing the SOP and improve employee engagement by conducting employee engagement survey. <br /> <br /> The control phase must be conducted and completed within a certain period of time for further review. Once the control phase is complete, the team will review and discuss whether further improvement is necessary. <br />