Sakti Lesmana - Academia.edu (original) (raw)
Papers by Sakti Lesmana
International Journal of Advances in Scientific Research and Engineering
The purpose of this study is to measure the machine’s performance in the filling process which of... more The purpose of this study is to measure the machine’s performance in the filling process which often experiences damage to one of the companies engaged in the food sector that produces coffee and goat milk powder sachet packaging. The company targets the production process results on coffee products as much as 15,600 sachets per day. In Filling Line 3 machines, there are often losses caused by machine breaks, so the daily production target is not achieved. The method used is the machine performance measurement method (OEE) which consists of 3 factors, namely Availability, Performance, and Quality. The results of the study were obtained from the Overall Equipment Effectiveness (OEE) value for the period of December 2021 (53.4%), January 2022 (60.6%), February 2022 (61%), and March 2022 (63.3%). The OEE value obtained from the calculation is still too far from the World Class standard (85%). The factors in the Six Big Losses analysis that caused the low OEE value consisted of Equipmen...
International Journal of Advances in Scientific Research and Engineering
Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean ... more Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean approach, followed by looking at the winding process as a whole, Big Picture Mapping and identification of waste that occurs in business processes, carried out by comparing the actual time to the standard time for the winding process, the value-adding time for the winding process is 21310 minutes. In contrast, the total production time is about 22995 minutes. The non-value-addingtime ,whichdoes not add value to the product, is 1685 minutes, and identified the causefor the delayusing Root Cause Analysis. Waste waiting is the most waste among other wastes.Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean approach, followed by looking at the winding process as a whole, Big Picture Mapping and identification of waste that occurs in business processes, carried out by comparing the actual time to the standard time for the winding process, the valu...
International Journal of Engineering Research and Advanced Technology
An automotive manufacturer is known PT Denso Indonesia. Due to the various losses that occurred i... more An automotive manufacturer is known PT Denso Indonesia. Due to the various losses that occurred in the Tube Welding Radiator Machine, PT Denso Indonesia saw a decline in the volume of production while creating its products. Evaluating the efficiency of the Tube Welding Radiator Machine production process is vital in order to identify and reduce any losses that may arise. This study's objectives are to assess the Tube Welding Machine's efficiency using the Overall Equipment Efficientness (OEE) method, compute the cost of six major losses, pinpoint their causes using Fishbone Analysis, offer suggestions for improvement, and then put those suggestions into practice to raise the Tube Welding Machine's efficiency. The average value of the measurement findings for the Tube Welding Radiator machine's Overall Equipment Effectiveness (OEE) value is 83.16 percent. Reduced speed losses resulting from the time lost during the production process account for the largest loss time ...
International Journal of Engineering Research and Advanced Technology, 2022
PT X is a manufacturing company engaged in the manufacture of automotive components. This company... more PT X is a manufacturing company engaged in the manufacture of automotive components. This company is a joint venture between an Indonesian company and a Japanese company. The company's main products are grouped into Drive Train, Engine Related Part, and Body Related Part. As a multinational company, the company's ability to maintain efficiency is very important. Of course, to keep the market competitive and to win the competition. One of the efficiencies that must be done is to reduce unproductive time, namely time that does not produce products. This research will focus more on the timing of the model changeover. Product XZ is one of the superior products of PT. X, but from the data obtained, this production line only has an effective time of 73% of the total working hours. This is due to the high time to change the model on the work track. The time to change the model reaches 25.75 minutes. So that the maximum production capacity is 5,968 pcs / day. To solve this problem, the Single Minutes Exchange of Dies (SMED) method is used. By implementing the 7 steps of SMED and supported by problem analysis using Pareto diagrams and why-why analysis, improvement in Production time productivity is increased by 25.3%, whereas, the productivity of the production line shows improvement from 6.94 parts/minute to 8.70 parts/minute.
International Journal of Engineering Research and Advanced Technology, 2020
Productivity has become a holistic target in any manufacturing company. Performance evaluation fo... more Productivity has become a holistic target in any manufacturing company. Performance evaluation for production areas in manufacturing should be measure by productivity index that already determined in company goals and targets. Currently, the productivity index has been measured by simple calculation, which only considering production result, manpower and working hours. Those calculations still cannot meet management desire about real productivity itself. Management needs productivity also considering some other performance, those are including quality rate, rework rate, manpower, working hour, production result, energy usage, and compliance with the schedule as input. This desire was mentioned in a company mission to be worldclass manufacturing. A well-known method as an objective matrix would be used for measuring the productivity index in the company. There would be a different rank of productivity after considering all of the mentioned items when compared with the currently used method. Production could be bigger than other month but on the other hand quality rate and rework, the rate was dropped. Than rank for productivity index in this company would be more complex and could be used as a raw model of productivity measurement internally or externally.
Puji syukur penulis panjatkan kepada Allah SWT atas karunia dan berkat yang dilimpahkanNYA kepada... more Puji syukur penulis panjatkan kepada Allah SWT atas karunia dan berkat yang dilimpahkanNYA kepada penulis sehingga penelititan ini dapat diselesaikan dalam waktu yang telah ditentukan. Pada kesempatan ini penulis juga ingin
Every company, especially manufacturing companies are required to make efficiency in each line to... more Every company, especially manufacturing companies are required to make efficiency in each line to increase productivity in order to compete with other companies. With the increasing demand for new products from customers, or usually called a New Project, companies are challenged to utilize the work area as much as possible with the existence of new production lines to meet the customer's demand. To do that, the company should immediately make improvements on all lines so that free space will be obtained which will be used for new projects. To reduce the Lead Time on the line in the production department with the expectation to get an optimal working area which creating space to be used for a New Project. Using the Value Stream Mapping method as a first step to mapping the entire process from upstream to downstream to identify Lead Time and lead to waste in each process. High waste occurs in the inventory lead time. Non-value added activities are mostly found in the inventory par...
Lean Manufacturing Implementation to Reduce Waste Using the Waste Assessment Model Method in the Production Process
International Journal of Engineering Research and Advanced Technology
The research carried out aims to identify, reduce, and hopefully eliminate waste on the Injection... more The research carried out aims to identify, reduce, and hopefully eliminate waste on the Injection Phylon production line using the lean manufacturing concept. One of the tools in lean manufacturing, namely the Waste Assessment Model (WAM) is used to identify waste in the production process. Using the WAM method, it was found that inventory waste is a critical waste with a value of 21.41%, while the second place is defect waste with a value of 20.37% and the third is overproduction waste with a value of 17.49%. After calculating with WAM, calculations are performed using the Value Stream Analysis Tools (VALSAT) to assist in seeing the mapping of existing waste. Using the VALSAT method with the Process Activity Mapping tools, it is found that storage is the largest activity with a value of 85.63%. The critical waste found in this study using WAM and VALSAT is inventory waste. Based on the fishbone analysis, it is found that the root cause of inventory waste is due to the absence of a real-time work order (SPK) information system in the production section and there is no standard identification of manufactured goods. Key Words: Lean manufacturing, waste assessment model, value stream analysis tools, fishbone
International Journal of Engineering Research and Advanced Technology
As we might know that work and safety has become one of lean foundation that mentioned in lean ho... more As we might know that work and safety has become one of lean foundation that mentioned in lean house along with heijunka, KANBAN, SEIRYUNKA, STABILIZATION, JIT, KAIZEN and JIDOKA. Safety is number one or as priority is reflected in Anzen Daiichi which includes the establishment of a Health and Safety Committee. One of the fields of study studied in occupational safety is how to make anticipation when a fire emergency occurs. In addition to fire suppression so that it does not spread, the most important thing is to save the workforce in the building or around the fire. It is also mentioned in the Indonesian Minister of Public Works Decree "KEPMEN No.10 / KPTS / 2000"," PERMEN No.26 / PRT / M / 2008", concerning about Technical Requirements of Fire Protection Systems in Buildings and the Environment. This study will focus on the feasibility of emergency exit facilities at labour-intensive companies with a workforce of more than 15,000 employees. An evaluation of the adequacy of the facility will also provide an overview of how well the layout design is done in anticipation of an emergency. Comparison of theoretical emergency exit needed with actual exist in factory would be used as reference to improve leadership knowledge and could be used to strengthen analysis of emergency plan at the audit tools from customer. Theoretical calculation result of Emergency Exit required in PT. PIN is very sufficient when compared to the existing rules.
Pengecoran adalah suatu proses manufaktur yang menggunakan logam cair dan cetakan untuk menghasil... more Pengecoran adalah suatu proses manufaktur yang menggunakan logam cair dan cetakan untuk menghasilkan parts dengan bentuk yang mendekati bentuk geometri akhir produk jadi. Logam cair akan dituangkan atau ditekan ke dalam cetakan yang memiliki rongga sesuai dengan bentuk yang diinginkan. Setelah logam cair memenuhi rongga dan kembali ke bentuk padat, selanjutnya cetakan disingkirkan dan hasil cor dapat digunakan untuk proses sekunder. Pasir hijau untuk pengecoran digunakan sekitar 75 percent dari 23 million tons coran yang diproduksi dalam USA setiap tahunnya. Untuk menghasilkan tuangan yang berkualitas maka diperlukan pola yang berkualitas tinggi, baik dari segi konstruksi, dimensi, material pola, dan kelengkapan lainnya. Pola digunakan untuk memproduksi cetakan. Pada umumnya, dalam proses pembuatan cetakan, pasir cetak diletakkan di sekitar pola yang dibatasi rangka cetak kemudian pasir dipadatkan dengan cara ditumbuk sampai kepadatan tertentu. Pada lain kasus terdapat pula cetakan yang mengeras/menjadi padat sendiri karena reaksi kimia dari perekat pasir tersebut. Pada umumnya cetakan dibagi menjadi dua bagian yaitu bagian atas dan bagian bawah sehingga setelah pembuatan cetakan selesai pola akan dapat dicabut dengan mudah dari cetakan. Inti dibuat secara terpisah dari cetakan, dalam kasus ini inti dibuat dari pasir kuarsa yang dicampur dengan Airkaca (Water Glass / Natrium Silikat), dari campuran pasir tersebut dimasukan kedalam kotak inti, kemudian direaksikan dengan gas CO2 sehingga menjadi padat dan keras. Inti diseting pada cetakan. Kemudian cetakan diasembling dan diklem. Sembari cetakan dibuat dan diasembling, bahan-bahan logam seperti ingot, scrap, dan bahan paduan, dilebur di bagian peleburan. Setelah logam cair dan homogen maka logam cair tersebut dituang ke dalam cetakan. Setelah itu ditunggu hingga cairan logam tersebut membeku karena proses pendinginan. Setelah cairan membeku, cetakan dibongkar. Pasir cetak, inti, dan benda tuang dipisahkan. Pasir cetak bekas masuk ke instalasi daur ulang, inti bekas dibuang, dan benda tuang diberikan ke bagian fethling untuk dibersihkan dari kotoran dan dilakukan pemotongan terhadap sistem saluran pada benda tersebut. Setelah fethling selesai apabila benda perlu perlakuan panas maka diproses di bagian perlakuan panas. Proses pengecoran sendiri dibedakan menjadi dua macam, yaitu traditional casting dan nontraditional/contemporary casting. Teknik traditional terdiri atas :
International Journal of Advances in Scientific Research and Engineering
The purpose of this study is to measure the machine’s performance in the filling process which of... more The purpose of this study is to measure the machine’s performance in the filling process which often experiences damage to one of the companies engaged in the food sector that produces coffee and goat milk powder sachet packaging. The company targets the production process results on coffee products as much as 15,600 sachets per day. In Filling Line 3 machines, there are often losses caused by machine breaks, so the daily production target is not achieved. The method used is the machine performance measurement method (OEE) which consists of 3 factors, namely Availability, Performance, and Quality. The results of the study were obtained from the Overall Equipment Effectiveness (OEE) value for the period of December 2021 (53.4%), January 2022 (60.6%), February 2022 (61%), and March 2022 (63.3%). The OEE value obtained from the calculation is still too far from the World Class standard (85%). The factors in the Six Big Losses analysis that caused the low OEE value consisted of Equipmen...
International Journal of Advances in Scientific Research and Engineering
Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean ... more Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean approach, followed by looking at the winding process as a whole, Big Picture Mapping and identification of waste that occurs in business processes, carried out by comparing the actual time to the standard time for the winding process, the value-adding time for the winding process is 21310 minutes. In contrast, the total production time is about 22995 minutes. The non-value-addingtime ,whichdoes not add value to the product, is 1685 minutes, and identified the causefor the delayusing Root Cause Analysis. Waste waiting is the most waste among other wastes.Minimizing all waste (waste) is mandatory for the company. The results of the study using a lean approach, followed by looking at the winding process as a whole, Big Picture Mapping and identification of waste that occurs in business processes, carried out by comparing the actual time to the standard time for the winding process, the valu...
International Journal of Engineering Research and Advanced Technology
An automotive manufacturer is known PT Denso Indonesia. Due to the various losses that occurred i... more An automotive manufacturer is known PT Denso Indonesia. Due to the various losses that occurred in the Tube Welding Radiator Machine, PT Denso Indonesia saw a decline in the volume of production while creating its products. Evaluating the efficiency of the Tube Welding Radiator Machine production process is vital in order to identify and reduce any losses that may arise. This study's objectives are to assess the Tube Welding Machine's efficiency using the Overall Equipment Efficientness (OEE) method, compute the cost of six major losses, pinpoint their causes using Fishbone Analysis, offer suggestions for improvement, and then put those suggestions into practice to raise the Tube Welding Machine's efficiency. The average value of the measurement findings for the Tube Welding Radiator machine's Overall Equipment Effectiveness (OEE) value is 83.16 percent. Reduced speed losses resulting from the time lost during the production process account for the largest loss time ...
International Journal of Engineering Research and Advanced Technology, 2022
PT X is a manufacturing company engaged in the manufacture of automotive components. This company... more PT X is a manufacturing company engaged in the manufacture of automotive components. This company is a joint venture between an Indonesian company and a Japanese company. The company's main products are grouped into Drive Train, Engine Related Part, and Body Related Part. As a multinational company, the company's ability to maintain efficiency is very important. Of course, to keep the market competitive and to win the competition. One of the efficiencies that must be done is to reduce unproductive time, namely time that does not produce products. This research will focus more on the timing of the model changeover. Product XZ is one of the superior products of PT. X, but from the data obtained, this production line only has an effective time of 73% of the total working hours. This is due to the high time to change the model on the work track. The time to change the model reaches 25.75 minutes. So that the maximum production capacity is 5,968 pcs / day. To solve this problem, the Single Minutes Exchange of Dies (SMED) method is used. By implementing the 7 steps of SMED and supported by problem analysis using Pareto diagrams and why-why analysis, improvement in Production time productivity is increased by 25.3%, whereas, the productivity of the production line shows improvement from 6.94 parts/minute to 8.70 parts/minute.
International Journal of Engineering Research and Advanced Technology, 2020
Productivity has become a holistic target in any manufacturing company. Performance evaluation fo... more Productivity has become a holistic target in any manufacturing company. Performance evaluation for production areas in manufacturing should be measure by productivity index that already determined in company goals and targets. Currently, the productivity index has been measured by simple calculation, which only considering production result, manpower and working hours. Those calculations still cannot meet management desire about real productivity itself. Management needs productivity also considering some other performance, those are including quality rate, rework rate, manpower, working hour, production result, energy usage, and compliance with the schedule as input. This desire was mentioned in a company mission to be worldclass manufacturing. A well-known method as an objective matrix would be used for measuring the productivity index in the company. There would be a different rank of productivity after considering all of the mentioned items when compared with the currently used method. Production could be bigger than other month but on the other hand quality rate and rework, the rate was dropped. Than rank for productivity index in this company would be more complex and could be used as a raw model of productivity measurement internally or externally.
Puji syukur penulis panjatkan kepada Allah SWT atas karunia dan berkat yang dilimpahkanNYA kepada... more Puji syukur penulis panjatkan kepada Allah SWT atas karunia dan berkat yang dilimpahkanNYA kepada penulis sehingga penelititan ini dapat diselesaikan dalam waktu yang telah ditentukan. Pada kesempatan ini penulis juga ingin
Every company, especially manufacturing companies are required to make efficiency in each line to... more Every company, especially manufacturing companies are required to make efficiency in each line to increase productivity in order to compete with other companies. With the increasing demand for new products from customers, or usually called a New Project, companies are challenged to utilize the work area as much as possible with the existence of new production lines to meet the customer's demand. To do that, the company should immediately make improvements on all lines so that free space will be obtained which will be used for new projects. To reduce the Lead Time on the line in the production department with the expectation to get an optimal working area which creating space to be used for a New Project. Using the Value Stream Mapping method as a first step to mapping the entire process from upstream to downstream to identify Lead Time and lead to waste in each process. High waste occurs in the inventory lead time. Non-value added activities are mostly found in the inventory par...
Lean Manufacturing Implementation to Reduce Waste Using the Waste Assessment Model Method in the Production Process
International Journal of Engineering Research and Advanced Technology
The research carried out aims to identify, reduce, and hopefully eliminate waste on the Injection... more The research carried out aims to identify, reduce, and hopefully eliminate waste on the Injection Phylon production line using the lean manufacturing concept. One of the tools in lean manufacturing, namely the Waste Assessment Model (WAM) is used to identify waste in the production process. Using the WAM method, it was found that inventory waste is a critical waste with a value of 21.41%, while the second place is defect waste with a value of 20.37% and the third is overproduction waste with a value of 17.49%. After calculating with WAM, calculations are performed using the Value Stream Analysis Tools (VALSAT) to assist in seeing the mapping of existing waste. Using the VALSAT method with the Process Activity Mapping tools, it is found that storage is the largest activity with a value of 85.63%. The critical waste found in this study using WAM and VALSAT is inventory waste. Based on the fishbone analysis, it is found that the root cause of inventory waste is due to the absence of a real-time work order (SPK) information system in the production section and there is no standard identification of manufactured goods. Key Words: Lean manufacturing, waste assessment model, value stream analysis tools, fishbone
International Journal of Engineering Research and Advanced Technology
As we might know that work and safety has become one of lean foundation that mentioned in lean ho... more As we might know that work and safety has become one of lean foundation that mentioned in lean house along with heijunka, KANBAN, SEIRYUNKA, STABILIZATION, JIT, KAIZEN and JIDOKA. Safety is number one or as priority is reflected in Anzen Daiichi which includes the establishment of a Health and Safety Committee. One of the fields of study studied in occupational safety is how to make anticipation when a fire emergency occurs. In addition to fire suppression so that it does not spread, the most important thing is to save the workforce in the building or around the fire. It is also mentioned in the Indonesian Minister of Public Works Decree "KEPMEN No.10 / KPTS / 2000"," PERMEN No.26 / PRT / M / 2008", concerning about Technical Requirements of Fire Protection Systems in Buildings and the Environment. This study will focus on the feasibility of emergency exit facilities at labour-intensive companies with a workforce of more than 15,000 employees. An evaluation of the adequacy of the facility will also provide an overview of how well the layout design is done in anticipation of an emergency. Comparison of theoretical emergency exit needed with actual exist in factory would be used as reference to improve leadership knowledge and could be used to strengthen analysis of emergency plan at the audit tools from customer. Theoretical calculation result of Emergency Exit required in PT. PIN is very sufficient when compared to the existing rules.
Pengecoran adalah suatu proses manufaktur yang menggunakan logam cair dan cetakan untuk menghasil... more Pengecoran adalah suatu proses manufaktur yang menggunakan logam cair dan cetakan untuk menghasilkan parts dengan bentuk yang mendekati bentuk geometri akhir produk jadi. Logam cair akan dituangkan atau ditekan ke dalam cetakan yang memiliki rongga sesuai dengan bentuk yang diinginkan. Setelah logam cair memenuhi rongga dan kembali ke bentuk padat, selanjutnya cetakan disingkirkan dan hasil cor dapat digunakan untuk proses sekunder. Pasir hijau untuk pengecoran digunakan sekitar 75 percent dari 23 million tons coran yang diproduksi dalam USA setiap tahunnya. Untuk menghasilkan tuangan yang berkualitas maka diperlukan pola yang berkualitas tinggi, baik dari segi konstruksi, dimensi, material pola, dan kelengkapan lainnya. Pola digunakan untuk memproduksi cetakan. Pada umumnya, dalam proses pembuatan cetakan, pasir cetak diletakkan di sekitar pola yang dibatasi rangka cetak kemudian pasir dipadatkan dengan cara ditumbuk sampai kepadatan tertentu. Pada lain kasus terdapat pula cetakan yang mengeras/menjadi padat sendiri karena reaksi kimia dari perekat pasir tersebut. Pada umumnya cetakan dibagi menjadi dua bagian yaitu bagian atas dan bagian bawah sehingga setelah pembuatan cetakan selesai pola akan dapat dicabut dengan mudah dari cetakan. Inti dibuat secara terpisah dari cetakan, dalam kasus ini inti dibuat dari pasir kuarsa yang dicampur dengan Airkaca (Water Glass / Natrium Silikat), dari campuran pasir tersebut dimasukan kedalam kotak inti, kemudian direaksikan dengan gas CO2 sehingga menjadi padat dan keras. Inti diseting pada cetakan. Kemudian cetakan diasembling dan diklem. Sembari cetakan dibuat dan diasembling, bahan-bahan logam seperti ingot, scrap, dan bahan paduan, dilebur di bagian peleburan. Setelah logam cair dan homogen maka logam cair tersebut dituang ke dalam cetakan. Setelah itu ditunggu hingga cairan logam tersebut membeku karena proses pendinginan. Setelah cairan membeku, cetakan dibongkar. Pasir cetak, inti, dan benda tuang dipisahkan. Pasir cetak bekas masuk ke instalasi daur ulang, inti bekas dibuang, dan benda tuang diberikan ke bagian fethling untuk dibersihkan dari kotoran dan dilakukan pemotongan terhadap sistem saluran pada benda tersebut. Setelah fethling selesai apabila benda perlu perlakuan panas maka diproses di bagian perlakuan panas. Proses pengecoran sendiri dibedakan menjadi dua macam, yaitu traditional casting dan nontraditional/contemporary casting. Teknik traditional terdiri atas :