Continuation of the Lean Manufacturing approach

Oct 13, 2025 by vinooalluri.com 11 views

Introduction

In today's competitive business landscape, companies are constantly seeking ways to improve their operational efficiency and reduce waste. One approach that has gained significant attention in recent years is the Lean Manufacturing method. This approach focuses on reducing waste and increasing added value for consumers by analyzing and optimizing the production process. In this article, we will explore the application of the Lean Manufacturing approach in NASA Karya Engineering UKM, a small and medium-sized enterprise (SME) that specializes in agricultural processing machines.

Background

NASA Karya Teknik, located on Jalan Karya Wisata, is a leading manufacturer of agricultural processing machines in the region. One of its most popular products is the Chopper Shredder, which is in high demand due to its efficiency and effectiveness. However, as the company's production capacity increased to meet the growing demand, several inefficiencies arose in the manufacturing process. These inefficiencies included excessive activities, inefficient workplace allocation, and waiting times, where workers were unemployed waiting for the process handled by other operators.

The Problem

The inefficiencies in the manufacturing process resulted in a significant impact on the company's operational costs and productivity. Excessive inspection activities and waiting times not only increased the process time but also minimized the use of unnecessary resources. This contributed to cost reduction and increasing customer satisfaction due to faster delivery time. However, the company was struggling to identify and eliminate the activities that did not add value to the production process.

The Solution

To address this problem, the company employed the Lean Manufacturing approach through the Value Stream Mapping (VSM) method. The VSM method is a powerful tool that helps companies visualize the flow of production processes and identify points that are a source of waste. By using the 5W+1H method, the analysis was carried out to dig deeper about wasteful sources. The 5W+1H method involves identifying what is the problem (what), the cause (why), the location of the problem (WHERE), who is involved (WHO), when the problem occurs (when), and how to fix it (how).

Methodology

The data collection was done by calculating the average time for each description of the production activity. The Process Activity Mapping tool was then used to identify activities that do not provide added value. The results of the analysis showed that there were several activities that did not provide added value, including three inspection activities and one delay activity.

Results

After an improvement of these activities, it was found an increase of 6% in the percentage of activities that gave added value, from 50% to 56%. In addition, the process time was also successfully reduced by 1,824.43 minutes, from the beginning of 3,003.43 minutes to 1,179 minutes.

Discussion

The application of the Lean Manufacturing approach in UKM NASA Karya Engineering shows how companies can improve their operational efficiency in a systematic way. Lean Manufacturing focuses on reducing waste and increasing added value for consumers. By applying value stream mapping, companies can get a clear picture of the flow of production processes and identify points that are a source of waste.

Excessive inspection activities and waiting times can have a significant impact on operational costs and productivity. By reducing or eliminating these activities, not only shorter process time, but also minimizes the use of unnecessary resources. This contributes to cost reduction and increasing customer satisfaction due to faster delivery time.

The application of the 5W+1H method also gives an in-depth perspective on existing problems. This method helps in identifying what is the problem (what), the cause (why), the location of the problem (WHERE), who is involved (WHO), when the problem occurs (when), and how to fix it (how). This approach is very useful to ensure that the proposed solution is not only effective, but also sustainable in the long run.

Conclusion

In conclusion, waste analysis with the Lean Manufacturing approach in NASA Karya Engineering UKM through the Value Stream Mapping method and 5W+1H analysis has shown significant results. This proves the importance of the application of lean methodology in small and medium industries, especially in increasing efficiency and reducing waste. Continuation of the steps taken can help this SME to remain competitive in meeting increasing market demand.

Recommendations

Based on the findings of this study, the following recommendations are made:

Continuation of the Lean Manufacturing approach: The company should continue to apply the Lean Manufacturing approach to further improve its operational efficiency and reduce waste.
Training and development: The company should provide training and development programs for its employees to ensure that they have the necessary skills and knowledge to implement the Lean Manufacturing approach.
Monitoring and evaluation: The company should regularly monitor and evaluate its progress in implementing the Lean Manufacturing approach to ensure that it is achieving its goals.

By following these recommendations, the company can continue to improve its operational efficiency and reduce waste, ultimately leading to increased customer satisfaction and competitiveness in the market.

Q: What is the Lean Manufacturing approach?

A: The Lean Manufacturing approach is a methodology that focuses on reducing waste and increasing added value for consumers by analyzing and optimizing the production process.

Q: What is Value Stream Mapping (VSM)?

A: Value Stream Mapping (VSM) is a powerful tool that helps companies visualize the flow of production processes and identify points that are a source of waste.

Q: What is the 5W+1H method?

A: The 5W+1H method is a problem-solving approach that involves identifying what is the problem (what), the cause (why), the location of the problem (WHERE), who is involved (WHO), when the problem occurs (when), and how to fix it (how).

Q: What are the benefits of implementing the Lean Manufacturing approach?

A: The benefits of implementing the Lean Manufacturing approach include increased efficiency, reduced waste, improved customer satisfaction, and increased competitiveness in the market.

Q: How can companies identify and eliminate waste in their production process?

A: Companies can identify and eliminate waste in their production process by using the Lean Manufacturing approach, which involves analyzing and optimizing the production process to reduce waste and increase added value.

Q: What is the role of training and development in implementing the Lean Manufacturing approach?

A: Training and development play a crucial role in implementing the Lean Manufacturing approach, as employees need to have the necessary skills and knowledge to implement the approach effectively.

Q: How can companies measure the success of their Lean Manufacturing implementation?

A: Companies can measure the success of their Lean Manufacturing implementation by tracking key performance indicators (KPIs) such as process time, waste reduction, and customer satisfaction.

Q: What are the challenges of implementing the Lean Manufacturing approach?

A: The challenges of implementing the Lean Manufacturing approach include resistance to change, lack of resources, and difficulty in measuring the effectiveness of the approach.

Q: How can companies overcome the challenges of implementing the Lean Manufacturing approach?

A: Companies can overcome the challenges of implementing the Lean Manufacturing approach by providing training and development programs for employees, allocating sufficient resources, and regularly monitoring and evaluating the effectiveness of the approach.

Q: What is the future of the Lean Manufacturing approach?

A: The future of the Lean Manufacturing approach is promising, as it continues to be a widely adopted methodology for improving operational efficiency and reducing waste in various industries.

Q: How can companies stay competitive in the market by implementing the Lean Manufacturing approach?

A: Companies can stay competitive in the market by implementing the Lean Manufacturing approach, which enables them to reduce waste, increase efficiency, and improve customer satisfaction, ultimately leading to increased competitiveness in the market.

Q: What are the key takeaways from this study on waste analysis with the Lean Manufacturing approach in NASA Karya Engineering UKM?

A: The key takeaways from this study are the importance of implementing the Lean Manufacturing approach to improve operational efficiency and reduce waste, the need for training and development programs for employees, and the importance of regularly monitoring and evaluating the effectiveness of the approach.