EVALUASI PENERAPAN LEAN MANUFACTURING DENGAN MENGGUNAKAN VALUE STREAM MAPPING DAN SIMULASI UNTUK MEREDUKSI MANUFACTURING LEAD TIME (STUDI KASUS: PT. ECCO INDONESIA)

Abstract

PT ECCO Indonesia is an export quality footwear company that has a strong commitment in implementing lean manufacturing. Implementation of lean manufacturing has to be evaluated periodically. To find out about the level of lean manufacturing implementation on the company current system and proposed fixes what can be given, then the evaluation performed by using value stream mapping and simulation. The first evaluation is done by making the big picture mapping of company. This mapping requires cycle time each process, that collected by the stopwatch time study method. The next stage is to rank the company waste to select an effective detailed mapping tools used in analyzing. That rank indicates that unnecessary motion has the highest weight. Then from the selection of detailed mapping tools, found that the tools chosen are the process activity mapping. Mapping the current state shows that the value added ratio based on the company's big picture mapping analysis was 0.62% while the analysis based on process mapping activity equal to 0.56%. The system is then analyzed and given some proposal improvement recommendation which have value added ratio equal to 0.93%. The proposals given in this study, among others, to train lean principles to the operator, applying the principles of 5S to the cutting component area, reducing the kanban trolley from three to two, reducing the amount of trolley that exist in the area between the injection and finishing, eliminating the non-value added activities, and reduce the amount and level of inventory in the warehouse of shoe upper material.