Meningkatkan Produktivitas Proses Perakitan Menggunakan Pendekatan Observasi Lapangan dan Prinsip Lean-Ergonomi di PT XYZ

Abstract

1. XYZ is a company engaged in automotive manufacturing and produces anti-vibration spare parts for cars. In addition to maintaining quality, manufacturing companies must also maximize the capacity of the machines and processes they have so that productivity can increase. However, along with the increasing number of orders, PT. XYZ faces constraints related to insufficient capacity, which requires additional working hours (overtime). This study aims to identify steps that can be taken to maximize the production process, so that the process load does not exceed the available capacity or cause additional work congestion, and increase output or productivity. This study was conducted using the observation method and analysis of the process, machines, and operator work. The results of the improvement showed that there were several factors that caused the output process to be less than optimal, including waiting time for one of the operators and the work of moving boxes containing products to the QA process, which resulted in fatigue and back pain in the operator. This caused a decrease in output and process capacity that could not compensate for the increased load due to the use of orders. As a countermeasure, line balancing and the addition of futapata one piece flow were implemented to ease the work of lifting boxes. By implementing line balancing and adding the output of one piece futapata flow, the output produced from 95 pcs increased to 105 pcs or equivalent to a 10% increase in productivity..