Penerapan Lean Manufacturing dalam Mengidentifikasi Waste pada Proses Produksi Bogie Frame TB 1014 di PT INKA (Persero)

Abstract

PT INKA (Persero) adalah perusahaan BUMN manufaktur kereta api pertama di Asia Tenggara yang memproduksi kereta api dan komponennya termasuk bogie. Bogie frame adalah bagian utama bogie untuk menahan beban dan guncangan saat kereta bergerak. Identifikasi pemborosan proses produksi bogie frame terdiri lima tahap: assy, rotary, forming, annealing, dan machining. Ditemukan discontinuity pengelasan, antrian proses, serta aktivitas tidak bernilai tambah yang menyebabkan inefisiensi. Untuk mengidentifikasi pemborosan, digunakan Lean Manufacturing dengan metode Value Stream Mapping dan Waste Assessment Model. Hasilnya, defect pemborosan dominan dengan final result tertinggi 23,47%. Process Activity Mapping bertujuan menganalisis aktivitas tidak bernilai tambah, mengefisiensi dari 58 menjadi 56 aktivitas, dengan penurunan lead time 15 jam 42 menit menjadi 15 jam 39 menit. Failure Mode and Effect Analys bertujuan menganalisis penyebab utama defect welding berdasarkan standar ISO 5817:2014. Analisis akar penyebab defect dengan Why – why Analys serta Kaizen 5W+1H, hasilnya, One Point Lesson dan future state mapping sebagai optimalisasi proses produksi.

PT INKA (Persero) is a state-owned enterprise railway manufacturing company in Southeast Asia, producing trains and their components including bogies. The bogie frame is the main part of the bogie to withstand loads and shocks when the trains is moving. Identified waste in the bogie frame production of five processes: assy, rotary, forming, annealing, and machining. Discontinuities, queue process and nonvalue added activity were found that cause inefficiency. Lean Manufacturing approach was applied using Value Stream Mapping and the Waste Assessment Model. The results indicate defects are the dominant waste, with the highest final result of 23.47%. Process Activity Mapping is used to analyze nonvalue added activities, which resulted in efficiency from 58 to 56 activities, with a lead time of 15 hours 42 minutes to 15 hours 39 minutes. Failure Mode and Effect Analysis aims to analyze the main causes of welding defects based on ISO 5817:2014. Root cause analysis of defects with Why-why analysis and Kaizen 5W+1H. The result, One Point Lesson and future state mapping as production process optimization.