Lean Manufacturing Implementation to Reduce Reject on Part Step Floor with DMAIC and FMEA approach

Abstract

 In this study, the problem is focused on the Cikarang plant, especially department warehouse 5 which is currently producing a new variant, the K2FA type. Because the mass production time for the K2FA type has not been running for a long time, there are still many adjustments that need to be made in the work process in order to create good effectiveness and efficiency. This has not been reflected in one of the supply processes, namely the preparation of the plastic eating step floor, because it was found that there was an additional process, namely the unpacking process and the new preparation train handling facilities which were considered inadequate, causing problems for manpower in the area. This problem begins with the high number of reject parts that reach a total of 11.5% percent in 5 months, therefore the potential for existing rejects must be identified in order to minimize the causes of waste as the goal of this study. The analysis phase is carried out using the DMAIC method (Define, Measure, Analyze, Improve, and Control), and use FMEA improvement analysis (Failure Mode and Effect Analysis). The results of this study are expected to be suggestions for minimizing waste.