Paulino Gamboa and Moses Laksono Singgih
Extended Abstract
This study aims to identify critical waste, find the causative factor, and make recommendations for improvements to critical waste that causes poor productivity in the company. To achieve this goal, the Lean Six Sigma, Eliminate, Combine, Rearrange, and Simplify (ECRS), and Theory of Inventive Problem (called TRIZ) methods will be applied to find non-value-added activities and provide improvement solutions to minimize critical waste. In the define stage, for Value Stream Mapping and identification of critical waste, the measurement stage looks for the DPMO value, Sigma level, and process capability. Then, the analysis stage analyzes the root causes of critical waste using 5-whys, and the improvement stage applies ECRS, TRIZ, and 5S. The results showed that defect waste was a critical waste (25%), DPMO 13128.75, the company’s Sigma level was at 3.7, and the process capability was 1.23. The 5-whys results show that: there is no means of transportation to replace employees, no formal quality standard, lack of awareness of health & safety, and immature mortar. The solution for minimizing waste defects is the need to conduct training and evaluate the implementation of the SOP. Carry out production floor cleaning. Install CCTV in the mixer to avoid re-mixing, adjusting the quality standards, requiring Concrete Block transportation equipment with better automation level.
Keywords: Eliminate, Combine, Rearrange, and Simplify (ECRS), Lean Six Sigma, Theory of Inventive Problem (TRIZ), Waste, 5S
1. INTRODUCTION
In today’s competitive business world, companies that can survive can adapt to the business environment so that it avoids problems that come at any time. One of the causes of the problem is the lack of productivity which causes competitiveness (Aparicio et al., 2016). The problem of productivity is one of the complex problems faced by organizations. Productivity measures the ratio between inputs responsibly to produce outputs that are beneficial to consumers or users. Productivity is an essential measure in manufacturing operations and turnover and profit, as it provides insight into the efficiency and effectiveness of operations. Productivity is also referred to as the effectiveness and efficiency that companies use to convert inputs into outputs: a measure of the effectiveness and efficiency of an organization in producing outputs with available resources. Productivity is the ratio of two scalars, aggregate output and aggregate input (Aparicio et al., 2016).
2. METHODOLOGY
- Define
- Measure
- Analysis and Improvement
3. RESULTS
1. Define:
This study discusses defects in the Concrete Block production process at the CBBI company in February 2021. The current VSM shows that the cycle time is 106 minutes. Of the total cycle time, the time for value-added activities (4 activities) is only 38 minutes, or equivalent to 36% of the total cycle time. Meanwhile, the necessary non-valueadded (18) and non-value added (4) activities are 51% and 13% of the total cycle time, respectively. The existence of necessary non-value-added activities and non-value-added activities indicates waste in the Concrete Block production process. In addition, the define stage also finds critical activities; the result is that defect waste is the most critical waste with a percentage of 25%.
2. Measure
3. Analyze
4. CONCLUSIONS
- The VSM shows that the cycle time is 106 minutes. Of the total cycle time, the time for value-added activities is only 38 minutes, or equivalent to 36% of the total cycle time. Meanwhile, the necessary non-value added and non-value-added activities are 51% and 13% of the total cycle time, respectively.
- The rank of waste based on the largest to the most negligible Weight, namely: Waste of Defects with a weight value of 25%, Waste of Motion with a weight value of 18% Waste of Transportation with a weight value of 17%, Waste of Waiting with a weight value of 15%, Waste of Overprocessing with a weight value of 9%, Waste of Overproduction with a weight value of 8% and Waste of Inventory 7%.