USULAN PENERAPAN LEAN MANUFACTURING UNTUK MENGURANGI LEAD TIME PRODUKSI PADA AREA SHEET PRESS FORMING DI PT DIRGANTARA INDONESIA

• Main Author: HARRY MARTUA SIMAMORA NIM 13414080, RICARDO
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/30416
• Institution: Institut Teknologi Bandung

PT Dirgantara Indonesia is one of the State-Owned Enterprises (SOEs) engaged in the aircraft manufacturing industry. One of the main areas for fabricating is the sheet press forming area. The process carried out in this area includes cutting the plate, smoothing the surface of the plate, pressing, and finish forming to improve the shape of the component. Based on the company's historical data, in the period January to September 2017, the company was unable to achieve the 96% of component target done in a timely manner. According to the management, the failure to achieve this target is due to high production lead time and waste in the production area of the sheet press forming area. Therefore, the lean manufacturing approach is being applied to identify and eliminate waste as to reduce production lead time. <br /> <br /> Lean manufacturing is made up of 3 main parts, namely making a map of the current state, analyzing the current state map, and designing a map of future conditions. In the current state mapping phase, mapping is done using value stream mapping (VSM). In addition, to detail activities on the production floor, entities and activities carried out are mapped using a cross-functional flowchart. In the current map making phase, 5whys analysis is used to identify waste. After knowing the root of the problem of waste, improvement was done to eliminate waste. The results of the improvement are then mapped into a map of future conditions. Finally, the conditions before and after the improvement is compared and analyzed. <br /> <br /> Based on VSM and cross-functional chart, the value added activity is only by 6,43% with lead time 3598,44 minutes. From the results of finding waste, found 3 main wastes that occur, namely waiting activities, over-processing, and unnecessary movements. To overcome the waste of waiting activities, load distribution is carried out to avoid imbalance of load between work stations which often causes waiting times between work stations. Overprocessing is minimized by training the operators to make them have uniform skills. To reduce unnecessary movements, standardization of work stations is carried out through the application of the 5S principle. From these improvements proposed, waste in the sheet press forming area can be minimized. The value added process is added to 13,27% with lead time 1743,98 minutes.