LEAD-TIME IMPROVEMENT OF KAM CUTTER PROCESSING USING THE POKA-YOKE METHOD AT A MANUFACTURING COMPANY IN CIKARANG

Singgih Juniawan, Saiful Hendra, Hasbullah Hasbullah, Uti Roysen, D Daruki, Eka Irawanti

Abstract


The KAM Cutter is a cutting blade used to manufacture plastic pellets through underwater pelletizing. A manufacturing company in Cikarang reported that, on average, an order completion rate for KAM Cutter for 2023-2024 was 12,51%, which is highly below expectations. This research will improve production capacity by enhancing lead time on the production floor. Lean Manufacturing tools used in the research involve Value Stream Mapping, Fishbone Diagram, Poka-Yoke, and Fixture Design. The findings of this research have revealed that by using a new fixture design, the CNC Milling process can reduce the lead time from 15,24 minutes to 2,09 minutes per unit and reduce the Surface Grinding process from 14,88 minutes to 0,87 minutes per unit while maintaining an overall lead time reduction of 84,38%, from 32 minutes to 5 minutes per unit. The above improvements increased production capacity from 6.507 units/year to 49.518 units/year, approaching the target of 54.000 units/year while boosting the company's revenue from IDR 2,47 billion to IDR 18,81 billion per year. Besides, the Non-Value-Added process time was reduced by 68,72%, reflecting significant efficiency improvements in the production process.

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References


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