Abstract

This company is engaged in garment manufacturing, producing various types of clothing. One of the products produced is polo shirts with a make-to-order (MTO) production system. From the results of observations that have been made, it is known that there is much waste that occurs on the production line. The waste that occurs is product defects, transportation, and waiting waste. Based on these problems, research was conducted using lean manufacturing to increase production and reduce waste using Value Stream Mapping (VSM), Value Stream Analysis Tools (VALSAT), fishbone diagrams, and 5 Why is Analysis to identify the production process flow from start to finish. The production process is completed, and the root cause of waste is. Based on the results, the lead time value was 346.50 minutes on the current value stream map, NVA activity was 54.17 minutes, NNVA activity was 32.10 minutes, and defects were 5%. Proposed improvements to be implemented in the company to reduce waste are by providing suggestions for maintenance activities, warning signs, additions, and utilization of work facilities. Carrying out the proposed improvements that have been given can result in a reduction in the total lead time of 13.78 minutes, an increase in process cycle efficiency of 1.65% and a reduction in the defect rate of 1% from a value of 5% to 4% based on the results of future value stream mapping.

Keywords

Waste, Lean Manufacturing, VSM, VALSAT