Track: Manufacturing

Abstract

The purpose of this study is to minimize waiting waste and defect waste in an effort to reduce unproductive time and defects in the production of press machines at PT XYZ in accordance with the Lean Manufacturing concept. The problem with waiting waste is the high time of miss feed, inspection, DF fault, and product repair, while the problem with defect waste is a large number of lump defects. Resolving the defect waste problem certainly reduces the time for inspection and repair because the main problem is interconnected, namely ibutsu. The solution for the miss feed and DF faults is the redesign of the scrap drain, a stopper for fixing materials, and a vacuum protector with the Poka-Yoke concept. Meanwhile, the solution for defective waste is proposed to change the cleaning system to prevent ibutsu on dies with the PDCA concept (Plan, Do, Check, Act). The prediction for the total time that can be reduced after solving the waiting waste problem is 1,786.5 minutes, and the completion of the defect waste is predicted to reduce the percentage of defects from 2.48% to 0.5%.