The Identification and Elimination of Waste Activities in The Gray Yarn Processing Company
DOI:
https://doi.org/10.14421/jiehis.4913Keywords:
lean manufacturing, value stream mapping, minimize wasteAbstract
This study aims to identify the types of waste and recommend improvements to minimize waste that occurs in the gray yarn processing company. Value Stream Mapping (VSM) is used to analyze the flow of materials and information throughout the production process. The main objective is to identify and eliminate waste, thereby improving efficiency and productivity in manufacturing operations. The biggest types of waste in the grey yarn processing production process of the preparation department are Unnecessary motion and Overprocessing waste types at 30% each, Unnecessary Inventory at 20%, and transportation at 20%. The recommendations given can reduce the overall leadtime from 58967 seconds to 58771 seconds.
References
Abolhassani, A., Layfield, K., & Gopalakrishnan, B. (2016). Lean And Us Manufacturing Industry: Popularity Of Practices And Implementation Barriers. International Journal Of Productivity And Performance Management, 65(7), 875-897. Https://Doi.Org/10.1108/Ijppm-10-2014-0157
Anuar, M. And Mansor, M. (2022). Application Of Value Stream Mapping In The Automotive Industry: A Case Study. Journal Of Modern Manufacturing Systems And Technology, 6(2), 34-41. Https://Doi.Org/10.15282/Jmmst.V6i2.8561
Arul, T., Arumugam, C., & Parthiban, P. (2014). Evaluation Of Lean Manufacturing Systems Using Madm And Fuzzy Topsis. Applied Mechanics And Materials, 592-594, 2628-2638. Https://Doi.Org/10.4028/Www.Scientific.Net/Amm.592-594.2628
Dadashnejad, A. And Valmohammadi, C. (2018). Investigating The Effect Of Value Stream Mapping On Operational Losses: A Case Study. Journal Of Engineering Design And Technology, 16(3), 478-500. Https://Doi.Org/10.1108/Jedt-11-2017-0123
Diah, H., Parkhan, A., & Sugarindra, M. (2018). Productivity Improvement In The Production Line With Lean Manufacturing Approach: Case Study Pt. Xyz. Matec Web Of Conferences, 154, 01093. Https://Doi.Org/10.1051/Matecconf/201815401093
Dora, M., Goubergen, D., Kumar, M., Molnár, A., & Gellynck, X. (2013). Application Of Lean Practices In Small And Medium-Sized Food Enterprises. British Food Journal, 116(1), 125-141. Https://Doi.Org/10.1108/Bfj-05-2012-0107
Fashtali, F., Langroudi, M., & Mahmoudabadi, A. (2016). Implementation Of Value Stream Mapping For Waste Elimination In Public Sectors: A Case Study At Emam Sajjad Clinic, Rasht, Iran. Public Health - Open Journal, 1(2), 40-47. Https://Doi.Org/10.17140/Phoj-1-109
Faulkner, W. And Badurdeen, F. (2014). Sustainable Value Stream Mapping (Sus-Vsm): Methodology To Visualize And Assess Manufacturing Sustainability Performance. Journal Of Cleaner Production, 85, 8-18. Https://Doi.Org/10.1016/J.Jclepro.2014.05.042
Firdaus, R. Z., & Wahyudin, W. (2023). Penerapan Konsep Lean Manufacturing Untuk Meminimasi Waste Pada PT Anugerah Damai Mandiri (Dam). Journal Of Integrated System (Jis) .
Gupta, V., Acharya, P., & Patwardhan, M. (2013). A Strategic And Operational Approach To Assess The Lean Performance In Radial Tyre Manufacturing In India. International Journal Of Productivity And Performance Management, 62(6), 634-651. Https://Doi.Org/10.1108/Ijppm-Jun-2012-0057
Henrique, D., Rentes, A., Filho, M., & Espôsto, K. (2015). A New Value Stream Mapping Approach For Healthcare Environments. Production Planning & Control, 27(1), 24-48. Https://Doi.Org/10.1080/09537287.2015.1051159
Johan, A., & Soediantoro, D. (2022). Literature Review Of The Benefits Of Lean Manufacturing On Industrial Performance And Proposed Applications In The Defense Industries. Journal Of Industrial Engineering & Management Research Vol.3 No. 2 .
Kasanah, Y. U., & Suryadhini, P. P. (2021). Identifikasi Pemborosan Aktivitas Di Lantai Produksi Psr Menggunakan Process Activity Mapping Dan Waste Assessment Model. Jurnal Intech Teknik Industri Universitas Serang Raya Vol 7no 2.
Kunyoria, J. (2022). A Literature Review And Research Agenda Of Value Stream Mapping Addressing Study Population And Sample Design. International Journal Of Progressive Sciences And Technologies, 34(2), 102. Https://Doi.Org/10.52155/Ijpsat.V34.2.3981
Laia, P., & Marwan. (2024). Penerapan Lean Manufacturing Untuk Meminimalkan Waste Pada Bagian Produksi Di Pt. Mechmar Jaya Industri. Jurnal Jtti (Jurnal Teknik Dan Industri).
Landry, J. And Ahmed, S. (2016). Adoption Of Leanness In The Manufacturing Industry. Universal Journal Of Management, 4(1), 1-4. Https://Doi.Org/10.13189/Ujm.2016.040101
Lasa, I., Laburu, C., & Vila, R. (2008). An Evaluation Of The Value Stream Mapping Tool. Business Process Management Journal, 14(1), 39-52. Https://Doi.Org/10.1108/14637150810849391
Manullang, M. M. (2020). Analisis Pengukuran Produktivitas Dengan Menggunakan Metode Mundel Dan Apc Di Pt X. Jurnal Optimasi Teknik Industri (2020) Vol. 02no. 01.
Maryadi, D., Tamalika, T., Ardaysi, M., Mz, H., & Azhari. (2023). Improvement Performa Gudang Medium Mile Dengan Menggunakan Value Stream Mapping Case Study: Warehouse Medium Mile Di Kota Palembang. Jurnal Ilmiah Manajemen, Bisnis Dan Kewirausahaan , Vol.3 No.1.
Ma'sum, A., & Setiafindari, W. (2022). Analisis Pemborosan Pada Proses Produksi Dengan Metode Value Stream Mappingdipt Mandiri Jogja Internasional. Jurnal Cakrawala Ilmiah.
Muñoz-Villamizar, A., Santos, J., García-Sabater, J., Lleó, Á., & Grau, P. (2019). Green Value Stream Mapping Approach To Improving Productivity And Environmental Performance. International Journal Of Productivity And Performance Management, 68(3), 608-625. Https://Doi.Org/10.1108/Ijppm-06-2018-0216
Nasution, A., Siregar, I., Nasution, T., Syahputri, K., & Rizkya, I. (2018). Lean Manufacturing Applications In The Manufacturing Industry. Matec Web Of Conferences, 220, 02005. Https://Doi.Org/10.1051/Matecconf/201822002005
Nielsen, H., Kristensen, T., & Grasso, L. (2018). The Performance Effects Of Complementary Management Control Mechanisms. International Journal Of Operations & Production Management, 38(11), 2124-2148. Https://Doi.Org/10.1108/Ijopm-09-2016-0577
Nordin, N., Deros, B., & Wahab, D. (2014). Lean Manufacturing Implementation In Malaysian Automotive Industry: An Exploratory Study. Operations And Supply Chain Management An International Journal, 21-30. Https://Doi.Org/10.31387/Oscm090053
Novitasari, R., & Iftadi, I. (2020). Analisis Lean Manufacturinguntuk Minimasi Wastepada Proses Door Pu. Jurnal Intech Teknik Industri Universitas Serang Raya Vol 6no 1.
Pei, X. And Pei, Z. (2016). Considering The Cost Analysis Of Value Stream In The Lean Improvement.. Https://Doi.Org/10.2991/Etmhs-16.2016.139
Qureshi, K., Mewada, B., Alghamdi, S., Almakayeel, N., Qureshi, M., & Mansour, M. (2022). Accomplishing Sustainability In Manufacturing System For Small And Medium-Sized Enterprises (Smes) Through Lean Implementation. Sustainability, 14(15), 9732. Https://Doi.Org/10.3390/Su14159732
Rahani, A. And Al-Ashraf, M. (2012). Production Flow Analysis Through Value Stream Mapping: A Lean Manufacturing Process Case Study. Procedia Engineering, 41, 1727-1734. Https://Doi.Org/10.1016/J.Proeng.2012.07.375
Saad, S., Bahadori, R., Bhovar, C., & Zhang, H. (2023). Industry 4.0 And Lean Manufacturing – A Systematic Review Of The State-Of-The-Art Literature And Key Recommendations For Future Research. International Journal Of Lean Six Sigma. Https://Doi.Org/10.1108/Ijlss-02-2022-0021
Saleem, G. (2022). Impact Of Lean Manufacturing On Organizational Performance Through A Moderating Role Of Erp. Samr, 51-65. Https://Doi.Org/10.57044/Samr.2022.1.2.2212
Sarifudin, M., Mansor, M., & Safiei, W. (2019). Waste Simplification For Warehouse Using Boolean Logic. International Journal Of Engineering Technology And Sciences, 5(1), 44-52. Https://Doi.Org/10.15282/Ijets.V5i1.2822
Sharmak, D. T. (2022). Hybrid Simulation For Value Stream Mapping To Improve The Environmental Performance Of The Construction Phase . Proceedings Of The 30th Annual Conference Of The International Group For Lean Construction (Iglc30).
Singh, R., Kumar, S., Choudhury, A., & Tiwari, M. (2006). Lean Tool Selection In A Die Casting Unit: A Fuzzy-Based Decision Support Heuristic. International Journal Of Production Research, 44(7), 1399-1429. Https://Doi.Org/10.1080/00207540500272980
Singh, S., Dixit, S., Sahai, S., Sao, A., Kalonia, Y., & Kumar, R. (2018). Key Benefits Of Adopting Lean Manufacturing Principles In Indian Construction Industry. Matec Web Of Conferences, 172, 05002. Https://Doi.Org/10.1051/Matecconf/201817205002
Varela, L., Araújo, A., Ávila, P., Castro, H., & Putnik, G. (2019). Evaluation Of The Relation Between Lean Manufacturing, Industry 4.0, And Sustainability. Sustainability, 11(5), 1439. Https://Doi.Org/10.3390/Su11051439
Wirawan, S. T., & Suryati, A. (2023). Penerapan Konsep Lean Manufacturinguntuk Mendesain Ulang Tata Letak Fasilitas Di Industri Usaha Mikro Kecil Menengah. Bussman Journal: Indonesian Journal Of Business And Management.
Worley, J. And Doolen, T. (2015). Organizational Structure, Employee Problem Solving, And Lean Implementation. International Journal Of Lean Six Sigma, 6(1), 39-58. Https://Doi.Org/10.1108/Ijlss-12-2013-0058
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Dhinar Elma Arifa, Imam Djati Widodo, Erlangga Fausa
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
(c) The Author(s). This article is distributed under a Creative Commons Attribution-ShareAlike 4.0 International License.