Understanding the Current State of Production

Oct 13, 2025 by thesweetdesigns.com 29 views

Mending Lean Road: Improvement of Supply Chain System at PT. Cakra Compact Aluminum Industrial

Waste in the production process is the main enemy of efficiency. Every time and cost is wasted without producing added value for consumers is an adverse loss. PT. Cakra Compact Aluminum Industrial Medan, a company engaged in the processing of aluminum profiles and marketing its products abroad, experienced obstacles with long production lead time. This condition is caused by various waste, such as waiting for material, recurrent transportation, excess production, product defects, and excessive inventory.

Lean manufacturing is a method that focuses on reducing waste and increasing value-added time along the supply chain value chain. This approach is essential for companies like PT. Cakra Compact Aluminum Industrial to overcome the obstacles they face in their production process. By adopting lean manufacturing, companies can improve their efficiency, reduce waste, and increase their competitiveness in the global market.

Understanding the Current State of Production

To implement lean manufacturing at PT. Cakra Compact Aluminum Industrial, it is essential to understand the current state of production. This can be achieved by mapping the existing production conditions using several tools:

Activity Process (PAM) Mapping

Activity Process (PAM) Mapping is a visual tool that helps to identify activities that produce added value and activities that do not produce added value. This tool is essential in understanding the flow of the production process and identifying areas where waste can be reduced.

Gang Process Chart

A Gang Process Chart is a tool that displays the sequence of operations, the time needed, and the distance of the material transfer. This tool helps to identify the waste of transportation and movement, which is a significant contributor to the long production lead time experienced by PT. Cakra Compact Aluminum Industrial.

Quality Filter Mapping

Quality Filter Mapping is a tool that analyzes critical points in the production process that have the potential to cause product defects. This tool helps to identify areas where quality control measures can be implemented to reduce the risk of product defects.

Demand Amplified Mapping (DAM)

Demand Amplified Mapping (DAM) is a tool that helps to understand the fluctuations of demand and how it has an impact on the supply chain performance. This tool is essential in understanding the demand patterns and making adjustments to the production process to meet the changing demands.

Identifying the Root Causes of Waste

Once the current state of production is understood, the next step is to identify the root causes of waste. This can be achieved by using tools such as:

5WHY

5WHY is a root analysis method that helps to identify the root causes of waste through a series of questions "Why?". This tool is essential in understanding the underlying causes of waste and making adjustments to the production process to reduce waste.

Cause Effect Diagram (Ishikawa Diagram)

A Cause Effect Diagram (Ishikawa Diagram) is a tool that displays the causal relationship between the problem and the factors that affect the problem. This tool helps to identify the root causes of waste and make adjustments to the production process to reduce waste.

Proposed Improvements

The results of the root analysis of the cause are then outlined in Future State Mapping, which is an ideal picture of the production process after the implementation of lean manufacturing. Proposed improvements submitted include:

Improvement of Work Procedures

Improvement of work procedures is essential in clarifying and simplifying the workflow to reduce errors and waste. This can be achieved by implementing standard operating procedures and training employees on the new procedures.

Application of 5S

Application of 5S is a principle that helps to create an organized, clean, and efficient workplace. This principle includes five steps: Seiri (sort), Seiton (set in order), Seiso (shine), Seiketsu (standardize), and Shitsuke (sustain). By applying 5S, PT. Cakra Compact Aluminum Industrial can reduce waste and improve efficiency.

Layout Improvement

Layout improvement is essential in designing an optimal factory layout to minimize the distance of material transfer and increase production flow. This can be achieved by rearranging the production layout to reduce transportation and movement waste.

Reduction of Change Over Time with SMED

Reduction of change over time with SMED (Single Minute Exchange of Die) is a technique that helps to minimize the time needed to replace the tools and machines. This technique is essential in increasing flexibility and production efficiency.

Application of Kanban

Application of Kanban is a system that helps to control the flow of material and production. This system is essential in reducing excessive inventory and increasing responsiveness to demand.

Implementation Strategy

The implementation of the proposed improvement is described in a comprehensive implementation strategy, helping the company to achieve the goal of reduction in lead time. The implementation strategy includes:

Training and Education

Training and education are essential in educating employees on the new procedures and principles. This can be achieved by providing training sessions and workshops on lean manufacturing and its principles.

Implementation of New Procedures

Implementation of new procedures is essential in clarifying and simplifying the workflow to reduce errors and waste. This can be achieved by implementing standard operating procedures and training employees on the new procedures.

Monitoring and Evaluation

Monitoring and evaluation are essential in monitoring the progress of the implementation and evaluating the effectiveness of the proposed improvements. This can be achieved by setting key performance indicators (KPIs) and monitoring the progress against these KPIs.

Case Study

The case study shows that the reduction in lead time is 50.08% can be achieved through improvements made. These results are promising, and the potential for increasing efficiency can still be explored with the application of continuous improvement.

Conclusion

By applying lean manufacturing, PT. Cakra Compact Aluminum Industrial is able to improve the efficiency of the production process, reduce waste, and increase the competitiveness of companies in the global market. This change is not only beneficial for the company, but also for customers who will get high-quality products and shorter waiting times.

Q: What is lean manufacturing, and how does it relate to supply chain improvement?

A: Lean manufacturing is a method that focuses on reducing waste and increasing value-added time along the supply chain value chain. It is a systematic approach to identifying and eliminating waste in production processes, with the goal of improving efficiency, reducing costs, and increasing customer satisfaction.

Q: What are the main benefits of implementing lean manufacturing in a supply chain?

A: The main benefits of implementing lean manufacturing in a supply chain include:

Reduced lead times
Improved efficiency
Increased productivity
Reduced waste
Improved quality
Increased customer satisfaction

Q: What are some common types of waste that can be eliminated through lean manufacturing?

A: Some common types of waste that can be eliminated through lean manufacturing include:

Transportation waste
Inventory waste
Motion waste
Waiting waste
Overproduction waste
Defect waste

Q: How can lean manufacturing be applied to a supply chain?

A: Lean manufacturing can be applied to a supply chain through a variety of methods, including:

Mapping the supply chain to identify areas of waste
Implementing just-in-time (JIT) production
Reducing inventory levels
Improving transportation efficiency
Implementing quality control measures

Q: What are some common tools and techniques used in lean manufacturing?

A: Some common tools and techniques used in lean manufacturing include:

Value stream mapping (VSM)
Root cause analysis (RCA)
Fishbone diagram
Pareto chart
Kaizen events

Q: How can lean manufacturing be implemented in a company?

A: Lean manufacturing can be implemented in a company through a variety of steps, including:

Conducting a lean assessment to identify areas of waste
Developing a lean strategy and plan
Implementing lean tools and techniques
Training employees on lean principles and practices
Monitoring and evaluating progress

Q: What are some common challenges that companies face when implementing lean manufacturing?

A: Some common challenges that companies face when implementing lean manufacturing include:

Resistance to change from employees
Difficulty in identifying and eliminating waste
Limited resources and budget
Difficulty in measuring and evaluating progress
Difficulty in sustaining lean improvements over time

Q: How can companies overcome these challenges and successfully implement lean manufacturing?

A: Companies can overcome these challenges and successfully implement lean manufacturing by:

Providing training and education to employees
Conducting regular assessments and evaluations
Setting clear goals and objectives
Providing resources and support
Encouraging a culture of continuous improvement

Q: What are some best practices for implementing lean manufacturing in a supply chain?

A: Some best practices for implementing lean manufacturing in a supply chain include:

Conducting a thorough analysis of the supply chain to identify areas of waste
Developing a comprehensive lean strategy and plan
Implementing lean tools and techniques in a systematic and structured way
Providing training and education to employees
Monitoring and evaluating progress regularly

Q: How can companies measure the success of their lean manufacturing implementation?

A: Companies can measure the success of their lean manufacturing implementation by:

Tracking key performance indicators (KPIs) such as lead time, inventory levels, and quality
Conducting regular assessments and evaluations
Monitoring and evaluating progress against goals and objectives
Conducting surveys and feedback sessions with employees and customers

Q: What are some common mistakes that companies make when implementing lean manufacturing?

A: Some common mistakes that companies make when implementing lean manufacturing include:

Not conducting a thorough analysis of the supply chain
Not developing a comprehensive lean strategy and plan
Not providing training and education to employees
Not monitoring and evaluating progress regularly
Not sustaining lean improvements over time

Q: How can companies avoid these mistakes and successfully implement lean manufacturing?

A: Companies can avoid these mistakes and successfully implement lean manufacturing by:

Conducting a thorough analysis of the supply chain
Developing a comprehensive lean strategy and plan
Providing training and education to employees
Monitoring and evaluating progress regularly
Sustaining lean improvements over time through continuous improvement and innovation.