Pendekatan Lean Manufacturing pada Lintasan Produksi Family Produk Pannel PT Dirgantara Indonesia

Abstract

Abstract. PT Dirgantara Indonesia, through the Spirit Aerosystem Division, manufactures Airbus components but faces delays in fulfilling orders due to lengthy manufacturing lead times caused by inefficiencies. To address this issue, production line improvements were carried out using a lean manufacturing approach. The improvement process involved several stages: creating a SIPOC diagram, mapping information and material flow using Value Stream Mapping (VSM) for the current state, comparing takt time and cycle time, and identifying inefficiencies through the Waste Assessment Model (WAM), which includes the Waste Relationship Matrix (WRM) and Waste Assessment Questionnaire (WAQ). Types of waste were analyzed and addressed using the 5W+1H method, followed by proposing improvements and mapping the future state with VSM. Current VSM mapping indicates that the production manufacturing lead time reaches 5,658 minutes, while processing time is only 1,812 minutes. Several workstations, such as Pre-Cutting, have cycle times exceeding takt time. WAQ results reveal that the primary types of waste include motion, inventory, defect, waiting, overproduction, process, and transportation. After implementing the proposed improvements, the manufacturing lead time is estimated to decrease by 33.52%, from 3,568 minutes to 2,372 minutes.

Abstrak. PT Dirgantara Indonesia, melalui Spirit Aerosystem Division, memproduksi komponen Airbus namun menghadapi kendala keterlambatan dalam memenuhi pesanan akibat manufacturing lead time yang panjang dikarenakan inefisiensi. Untuk mengatasi masalah ini, dilakukan perbaikan lini produksi dengan pendekatan lean manufacturing. Proses perbaikan dilakukan dengan tahapan berikut : pembuatan diagram SIPOC, pemetaan alur informasi dan material menggunakan Value Stream Mapping (VSM) untuk kondisi saat ini, perbandingan antara takt time dan cycle time, serta identifikasi inefisiensi melalui Waste Assessment Model (WAM), yang melibatkan Waste Relationship Matrix (WRM) dan Waste Assessment Questionnaire (WAQ). Jenis pemborosan dianalisis dan diperbaiki menggunakan metode 5W+1H, dilanjutkan dengan usulan perbaikan dan pemetaan kondisi masa depan menggunakan VSM. Pemetaan VSM saat ini menunjukkan manufacturing lead time produksi mencapai 5.658 menit, sementara waktu pemrosesan hanya 1.812 menit. Beberapa stasiun kerja, seperti Pre-Cutting, memiliki cycle time yang melebihi takt time. Hasil WAQ menunjukkan jenis pemborosan utama mencakup motion, inventory, defect, waiting, over production, process, dan transportasi. Setelah usulan perbaikan diterapkan, manufacturing lead time diperkirakan berkurang sebesar 33,52%, dari 3.568 menit menjadi 2.372 menit.