IMPROVEMENT DESIGN OF COVER NUT PRODUCTION PROCESS USING LEAN MANUFACTURING APPROACH TO REDUCE REWORK ACTIVITIES
PT. NAGOYA is a company engaged in the rubber, polyvinyl chloride and plastic industry. PT. NAGOYA producing spare parts made from rubber for the needs of movable vehicles, such as seal switches, lever seals, safety regulators, seal buttons, R3, cover nuts, water reservoir tank caps, seal bracket, rubber discs, rubber dumper. Among all the products produced during the research, namely the seal switch, cover nut, seal bracket, and K3, the cover nut has the longest lead time, which is 71 minutes, there is a difference for 48 minutes with seal bracket, which is the most produced product. After further analysis, in the production process of cover nut, there is a reworked activity caused by waste defects in the cutting area. Cutting area has the highest defect value compared to other areas in the cover nut production process as much as 86.67%. The waste defect caused by an unsuitable result of cutting the compound. Efforts are being made to minimize waste defects and eliminate rework activities using lean manufacturing. Creating value stream mapping (VSM) and Process Activity Mapping (PAM) to map the flow of information and the flow of the production process. Next, identify the root of the waste defect using 5 whys. The problem of the waste defect will be solved by improving the design of cutting tools using the quality function deployment method and improving the system to the automatic using controller. After that, creating value stream mapping (VSM) current state and compared to value stream mapping (VSM) future state to find out the differences that occur after the implementation of the proposed design. The result obtained from the proposed design is stable cutting result caused by an automatic system so defects will be reduced and will eliminate rework activities in the cover nut production process at PT. NAGOYA so the production lead time will be reduced by 280,063 seconds or 8%.
Keywords: lean manufacturing, quality function deployment method, waste defect, controller, rubber
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