The Application of the Lean Manufacturing Method with an Ergonomics Approach

Oct 13, 2025 by vinooalluri.com 5 views

The Application of the Lean Manufacturing Method with an Ergonomics Approach to Minimize Waste at PT. Florindo Makmur

Introduction

In today's fast-paced and competitive business environment, companies are constantly seeking ways to improve their production processes, reduce waste, and increase efficiency. One such approach is the implementation of the Lean Manufacturing method, which focuses on eliminating waste and maximizing value-added activities. However, when combined with an ergonomics approach, the benefits can be even more significant. This article explores the application of the Lean Manufacturing method with an ergonomics approach at PT. Florindo Makmur, a company that faced significant challenges in terms of workers' efficiency and health.

The Challenges Faced by PT. Florindo Makmur

PT. Florindo Makmur, a leading manufacturer in the industry, faced numerous challenges in its production process. One of the most significant forms of waste was "Waste Waiting," which occurred when products were manually moved from the packaging station to the Forklift by operators. This not only drained their energy but also had the potential to cause health problems, especially when considering the standards set by the International Labor Organization (ILO). The ILO recommends a reduction in excessive workload to prevent health issues.

In addition to Waste Waiting, the packing process produced large amounts of flour dust, between 15 kg to 20 kg per day, which had a negative impact on the health of workers' breathing. The main problems arising from this situation included two aspects: First, Waste Waiting, which resulted in late delivery of products to warehouses, and secondly, inappropriate workloads that could cause health and safety problems of operators, and contribute to greater waste. Working posture that was not ergonomic played a major role in the waste, making it essential to implement effective improvements.

The Application of the Lean Manufacturing Method with an Ergonomics Approach

To overcome the problems faced by PT. Florindo Makmur, the application of the Lean Manufacturing method combined with an ergonomics approach was an ideal solution. Lean Manufacturing focuses on reducing waste in all stages of production, while the ergonomics approach aims to create a better work environment for employees, thereby improving occupational health and safety.

The implementation of the Lean Manufacturing method and the ergonomics approach at PT. Florindo Makmur involved several key steps. Firstly, a thorough analysis of the production process was conducted to identify areas of waste and inefficiency. Secondly, a team of experts was assembled to develop and implement solutions to address these issues. Finally, the solutions were implemented, and the results were monitored and evaluated.

The Results Achieved

After the implementation of the improvement, the results achieved were quite significant. Actual production time had decreased from 173.45 minutes to 160.53 minutes. In addition, the Cycle Efficiency process also showed improvement, moving from 83.61% to 90.33%. This showed that the reduction in Waste Waiting and the increase in ergonomics was not only beneficial for workers' health but also increased the overall production efficiency.

Conclusion

The application of the Lean Manufacturing method with an ergonomics approach at PT. Florindo Makmur not only helped in minimizing waste but also created a healthier and more productive work environment. This is an important step to ensure employee welfare and company sustainability in the long run. In conclusion, continuous improvement in the production process must be an integral part of the company's strategy to face future challenges.

Recommendations

Based on the results achieved, several recommendations can be made for companies seeking to implement the Lean Manufacturing method with an ergonomics approach. Firstly, a thorough analysis of the production process is essential to identify areas of waste and inefficiency. Secondly, a team of experts should be assembled to develop and implement solutions to address these issues. Finally, the solutions should be implemented, and the results should be monitored and evaluated.

Future Research Directions

Future research directions for this study include exploring the application of the Lean Manufacturing method with an ergonomics approach in other industries and companies. Additionally, further research is needed to investigate the impact of the Lean Manufacturing method with an ergonomics approach on employee welfare and company sustainability.

Limitations of the Study

This study has several limitations. Firstly, the study was conducted at a single company, and the results may not be generalizable to other companies. Secondly, the study focused on the application of the Lean Manufacturing method with an ergonomics approach, and other factors that may have influenced the results were not considered.

Conclusion

In conclusion, the application of the Lean Manufacturing method with an ergonomics approach at PT. Florindo Makmur was a successful initiative that helped to minimize waste, increase efficiency, and create a healthier and more productive work environment. This study highlights the importance of continuous improvement in the production process and the need for companies to adopt a holistic approach to improving their operations.
Frequently Asked Questions (FAQs) about the Application of the Lean Manufacturing Method with an Ergonomics Approach

Q: What is the Lean Manufacturing method?

A: The Lean Manufacturing method is a production methodology that focuses on eliminating waste and maximizing value-added activities. It aims to create a more efficient and effective production process by identifying and eliminating non-value-added activities.

Q: What is the ergonomics approach?

A: The ergonomics approach is a method of designing and arranging workspaces to reduce the risk of injury and improve the overall well-being of employees. It involves analyzing the physical and mental demands of a job and making changes to reduce the risk of injury and improve productivity.

Q: How does the Lean Manufacturing method with an ergonomics approach help to minimize waste?

A: The Lean Manufacturing method with an ergonomics approach helps to minimize waste by identifying and eliminating non-value-added activities and improving the efficiency of the production process. By reducing waste, companies can save time, money, and resources, and improve their overall competitiveness.

Q: What are the benefits of implementing the Lean Manufacturing method with an ergonomics approach?

A: The benefits of implementing the Lean Manufacturing method with an ergonomics approach include:

Improved efficiency and productivity
Reduced waste and costs
Improved employee health and well-being
Increased competitiveness
Improved customer satisfaction

Q: How can companies implement the Lean Manufacturing method with an ergonomics approach?

A: Companies can implement the Lean Manufacturing method with an ergonomics approach by:

Conducting a thorough analysis of their production process to identify areas of waste and inefficiency
Developing and implementing solutions to address these issues
Monitoring and evaluating the results of the implementation
Continuously improving and refining the production process

Q: What are the challenges of implementing the Lean Manufacturing method with an ergonomics approach?

A: The challenges of implementing the Lean Manufacturing method with an ergonomics approach include:

Resistance to change from employees and management
Limited resources and budget
Difficulty in identifying and addressing non-value-added activities
Need for ongoing training and education

Q: How can companies overcome the challenges of implementing the Lean Manufacturing method with an ergonomics approach?

A: Companies can overcome the challenges of implementing the Lean Manufacturing method with an ergonomics approach by:

Developing a clear and compelling business case for the implementation
Providing ongoing training and education for employees and management
Establishing a culture of continuous improvement and innovation
Encouraging employee participation and engagement in the implementation process

Q: What are the future directions for the Lean Manufacturing method with an ergonomics approach?

A: The future directions for the Lean Manufacturing method with an ergonomics approach include:

Expanding the application of the Lean Manufacturing method with an ergonomics approach to other industries and companies
Developing new and innovative solutions to address emerging challenges and opportunities
Continuously improving and refining the production process to stay competitive and innovative

Q: How can companies measure the success of the Lean Manufacturing method with an ergonomics approach?

A: Companies can measure the success of the Lean Manufacturing method with an ergonomics approach by:

Tracking and analyzing key performance indicators (KPIs) such as efficiency, productivity, and waste reduction
Conducting regular audits and assessments to identify areas for improvement
Gathering feedback and input from employees and customers
Continuously monitoring and evaluating the results of the implementation.