Lean production design using value stream mapping and ergonomics approach for waste elimination on buffing panel upright process

摘要

This study discussed the implementation of ergonomics and value stream mapping issues to reduce the existing waste in the process of buffing upright panel in the XYZ music manufacturing company. Aimed to identify the 9 waste based on the identification in terms of production processes and ergonomic factors, namely environmental health and safety, defects, overproduction, waiting, not utilizing employee knowledge skill and ability, transportation, inventory, motion, and excess process. In addition, ergonomics factors were identified, for example posture using REBA, job safety analysis, and physical workload. This study results indicated that the process is having 21.4% of the potential dangers that could not be accepted and thus potentially lead to lost time. Continued with the physical workload, the score of % cardiovascular load value is still below 30%, which means that the physical workload is normal and allows the addition of work. Meanwhile, in the calculation of posture investigation, the REBA resulted that there was a motion waste identified on the edge buff machine and ryoto with the score of 10 and 8. In conclusion, the results shown that there were 20 overall waste produced, then thus waste were reduced based on the identification and discussion of proposed improvements.