Analisa Penerapan Lean Manufacturing pada Sistem Produksi Girders Boxing Fabrication Process Untuk Mengeliminasi Waste (Studi Kasus : Departemen Produksi Cranes PT. MHE Demag Indonesia – Surabaya). (Analysis of the Application of Lean Manufacturing in the Girders Boxing Fabrication Process Production System to Eliminate Waste (Case Study: Cranes Production Department of PT. MHE Demag Indonesia – Surabaya)).

Hidayah, Manarul (2023) Analisa Penerapan Lean Manufacturing pada Sistem Produksi Girders Boxing Fabrication Process Untuk Mengeliminasi Waste (Studi Kasus : Departemen Produksi Cranes PT. MHE Demag Indonesia – Surabaya). (Analysis of the Application of Lean Manufacturing in the Girders Boxing Fabrication Process Production System to Eliminate Waste (Case Study: Cranes Production Department of PT. MHE Demag Indonesia – Surabaya)). Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

PT. MHE Demag Indonesia - Surabaya is a company engaged in manufacturing cranes - related goods in Indonesia. The company, headquartered at Duisburg, Nordrhein - Westfalen, Germany, manufactures a wide range of cranes, one of the most popular being industrial cranes. The company provides cranes on request (MTO) or on a made-to-order basis for all types of cranes. The problem faced by the company is that there are many wasted activities in the process of making cranes from girders in the boxing process, this results in the company not achieving the productivity standards expected by the company. To study the frequency of wasteful activities in the boxing girders manufacturing process, a lean approach to manufacturing is used, this approach is intended to reduce waste while providing a means of continuous improvement that will lead to efficiency in the process. In this research process, the Lean Manufacturing approach is used to analyze the presence of waste using the Waste Assessment Model (WAM) method, determine the dominant type of waste in the boxing girder manufacturing process using the Value Stream Mapping (VSM) method, and assess the value of the process using the Value Stream Analysis Tools (VALSAT). The causes and consequences of the process were then analyzed using the five whys method with a cause and effect diagram as a proposal for improvement in the box girder manufacturing process. The findings showed that the three largest categories of waste were over order waste (22.2%), inventory waste (17%), and motion waste (15.2%). Improvement suggestions were given to find out the main cause of the problem with a more detailed explanation using a combination of the cause and effect diagram method and the five whys analysis. After the proposed improvements were implemented, the boxing girders manufacturing process reduced time by 12.4 hours.

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