The purpose of this project is to analyze the implementing of the lean methodology to low volume car production. There are many problem occurs at the production line such as breakdown of the machine. The project has started with identifying problem at the AMM plant focus at the Trim and Finale Department. Then, the data has been analyzed by using Total Quality Management Tools such as fishbone diagram and Pareto chart. From the analysis, the main problem is come from two type of the machine which is the mount lift and overhead pulley. The losses will affect the losses to the company. Some lean tools are suggested to overcome the problems which are Total Productive Maintenance (TPM), Standardized Work, Continuous Improvement, 5S and others. There are the advantages of applying lean methodology to the car production such as increase worker’s discipline, eliminate the waste, and improve the quality of the product and others. There are some limitation of applying the lean methodology such as setup cost, cooperation within the administrator and operator and the company rules and policy. By applying the lean tools, the problem can be minimized and gain the high profit at the same time. The lean tools only can be suggested without implementation because of the rules and policy of the company.
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