INDUSTRIAL PRODUCTIVITY IMPROVEMENT USING LEAN MANUFACTURING APPROACH BASED ON SIMULATION MODEL (CASE STUDY IN PT INTI VULKATAMA)

DIRA, IRSANTI (2019) INDUSTRIAL PRODUCTIVITY IMPROVEMENT USING LEAN MANUFACTURING APPROACH BASED ON SIMULATION MODEL (CASE STUDY IN PT INTI VULKATAMA). Diploma thesis, UNIVERSITAS ANDALAS.

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Abstract

Industrial growth plays an important role in the nation's economic progress as the industry sector has superiority over other sectors. This advantage is a large capital capitalization-planting value, the ability to absorb large manpower, and the ability to create value added creation of each input or basic material is processed. In addition, the large industrial growth also indicates the high productivity of the industrial sector. Productivity in a company can be an indicator of success or failure of the company. Then, by increasing productivity, the company's strength in competition will also increase. PT. Inti Vulkatama is a manufacturing industry that processes rubber goods through the process of tyre vulcanizing. The process of tyre vulcanizing is the process of installation of new palms in the tires that have been bare through several procedures to be used again through cold process or heat process. The company suffered a decrease in productivity throughout the year 2016-2018 with a total decline in overall production reaching 7,467 units. This is due to the lead time and waste in the production process. On of the approach in the effort to improve productivity is to use lean manufacturing approach since it can describe the waste that occurs in the production floor. This research begins with an initial study in the form of a literature survey and field study. Then the Waste Relationship Matrix, Waste Assessment Questionnaire and Value Stream Analysis Tools was conducted and applied to determine the waste that occurs in the production process. The highest waste that occurred is motion by 25.34%, followed by defects 19.88%, and waiting 12.57%. After that, a simulation model is built to identify waste and test the impact of each repair solution scenario before it is implemented into the real system. Each solution scenario that is formulated is tested for economic feasibility to choose the optimal solution scenario. The results obtained from the study were chosen investment solution scenarios by adding 17 heat curing machines and using roller conveyor as material handling for material transfer activities between work stations. The surplus obtained at Rp 6,119,354 from profit with Net Present Value at Rp 3,300,844,956. Keywords: discrete event simulation, lean manufacturing, productivity, PT. Inti Vulkatama, tyre vulkanizing, waste.

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