Productivity improvement of assembly department by using value stream mapping and computer simulation approach

Abstract

Abstract As a matter of fact, productivity improvement is a common objective which are faced by almost every industry. Lean manufacturing is one critical key of success to achieve productivity by increasing effectivity and efficiency of an industry. A manufacturer which annually produces piano in a huge capacity has a target to improve the ability to satisfy its high demand. As a solution to the problem, this study focused on lean manufacturing design, specifically on assembly unit department. This study conducted by utilizing two methods, Value Stream Mapping and Computer Simulation technique as a system approaching tool. According to the problem identification stage using Current State Mapping, the productivity level on assembly unit department is only 0.27 unit/person/hour, still at below level of the productivity target 0.36 unit/person/hour. The problem indicates that there was many possible productions system matter, such as: production process input, which was not utilized in an optimum way, workload distribution that was not well-managed, and operator ability that is under specification. By using computer simulation approach, this study suggested couple of alternatives to answer the productivity problem.