Analysis of Production Process Waste Using Lean Manufacturing Approach at PT. XYZ

Abstract

Waste in the production process can reduce efficiency and hinder the smooth flow of production. This research aims to identify types of waste, analyze the causes of waste, and provide improvement suggestions using the Lean Manufacturing approach in the production process at PT XYZ. The methods used include Value Stream Mapping (VSM) to map the production flow, Process Activity Mapping (PAM) to identify value-added (VA), non-value-added (NVA), and necessary non-value-added (NNVA) activities, as well as Root Cause Analysis (RCA) to determine the root causes of waste. The research results show that the dominant wastes are waiting, inventory, and motion. Improvement proposals were made thru Future State Mapping (FSM) with layout improvements, preventive maintenance, and work in process (WIP) control. The improvement results show a reduction in processing time, a decrease in transfer distance, and an increase in production flow efficiency.