Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry
Abstract
Purpose: This study aims to improve Process Cycle Efficiency (PCE) by reducing waste in the assembly production line. This research is a case study conducted in a four-wheel vehicle manufacturing company to create a Lean production system.
Methodology/Approach: This study uses the Waste Assessment Model (WAM) and Lean Automation integration methods carried out by 5 expert judgements in the selected four-wheeled vehicle industry.
Findings: Based on the WAM method, this study found the biggest waste on the assembly line, namely transportation with a percentage of 20.44%. Improvements made with Lean Automation can increase the value of PCE from 56.76% to 63.62%.
Research Limitation/Implication: This research is limited to one model, namely Multi Purpose Vehicle (MPV). This research provides benefits for companies related to waste reduction. For similar companies, this research can be input for manufacturing practitioners in improving manufacturing performance to compete in the global market. This Lean production can reduce manpower which has an impact on saving production costs.
Originality/Value of paper: This paper provides added value related to the application of Lean terminology which aims to improve industrial automation-based manufacturing companies.
References
Asean Automotive Federation, 2020. Produksi Kendaraan Roda Empat di Kawasan ASEAN. [online] Available at: [Accessed 17 May 2021].
Chaurasia, B., Garg, D. and Agarwal, A., 2019. Lean Six Sigma approach: a strategy to enhance performance of first through time and scrap reduction in an automotive industry. International Journal Business Excellence, 17(1), pp.42-57. DOI: 10.1504/IJBEX.2019.096903.
Dănuţ-Sorin, I.R., Opran, C.G. and Lamanna, G., 2020. Lean Manufacturing 4.0 of Polymeric Injection Molding Products. Macromolecular Symposia, [e-journal] 389(1), pp.10-12. DOI: 10.1002/masy.201900109.
Garza-reyes, J.A., Sebastian, J., Forero, B., Kumar, V., Cedillo-campos, M.G. and Rocha-lona, L., 2017. Improving Road Transport Operations using Lean Thinking. Procedia Manufacturing, [e-journal] 11(June), pp.1900-1907. DOI: 10.1016/j.promfg.2017.07.332.
Habidin, N.F., Salleh, M.I., Latip, N.A. and Nor, M., 2016. Lean six sigma performance improvement tool for automotive suppliers. Journal of Industrial and Production Engineering, [e-journal] 33(4), pp.215-235. DOI: 10.1080/21681015.2015.1136966.
Henny, H. and Budiman, H.R., 2018. Implementation lean manufacturing using Waste Assessment Model (WAM) in shoes company. IOP Conference Series: Materials Science and Engineering, [e-journal] 407(1), pp.1-6. DOI: 10.1088/1757-899X/407/1/012077.
Ikatrinasari, Z.F., Hasibuan, S. and Kosasih, K., 2018. The Implementation Lean and Green Manufacturing through Sustainable Value Stream Mapping. International Conference on Design, Engineering and Computer Sciences, 453(1), pp.1-9. DOI: 10.1088/1757-899X/453/1/012004.
Irawati, D. and Charles, D., 2010. The involvement of Japanese MNEs in the Indonesian automotive cluster. International Journal Automotive Technology and Management, 10(2), pp.180-196. DOI:10.1504/IJATM.2010.032623.
Kaneku-Orbegozo, J., Martinez-Palomino, J., Sotelo-Raffo, F. and Ramos-Palomino, E., 2019. Applying Lean Manufacturing Principles to reduce waste and improve process in a manufacturer: A research study in Peru. IOP Conference Series: Materials Science and Engineering, [e-journal] 689(1), pp.1-7. DOI: 10.1088/1757-899X/689/1/012020.
Lacerda, A.P., Xambre, A.R. and Alvelos, H.M., 2016. Applying Value Stream Mapping to eliminate waste: A case study of an original equipment manufacturer for the automotive industry. International Journal of Production Research, [e-journal] 54(6), pp.1708-1720. DOI: 10.1080/00207543.2015.1055349.
Leksic, I., Stefanic, N. and Veza, I., 2020. The impact of using different lean manufacturing tools on waste reduction. Advances in Production Engineering & Management, [e-journal] 15(1), pp.81-92. DOI: 10.14743/apem2020.1.351.
Liker, J.K. and Meier, D., 2006. The Toyota Way Fieldbook - A Practical Guide for Implementing Toyota’s 4Ps. New York. McGraw-Hill.
Marifa, P.C., Andriani, F.Y., Indrawati, S., Parmasari, A.N., Budiman, H. and Kamilia, A., 2018. Production waste analysis using value stream mapping and waste assessment model in a handwritten batik industry. MATEC Web of Conferences, [e-journal] 154, pp.10-13. DOI: 10.1051/matecconf/201815401076.
Nallusamy, S. and Adil Ahamed, M.A., 2017. Implementation of lean tools in an automotive industry for productivity enhancement - A case study. International Journal of Engineering Research in Africa, [e-journal] 29(1), pp.175-185. DOI: 10.4028/www.scientific.net/JERA.29.175.
Narkea, M. and Jayadevab, C.T., 2020. Value Stream Mapping: Effective Lean Tool for SMEs. International Conference on Advances in Materials and Manufacturing Applications, [e-journal] 24(2), pp.1263-1272. DOI: 10.1016/j.matpr.2020.04.441.
Natsuda, K., Otsuka, K. and Thoburn, J., 2015. Dawn of Industrialisation? The Indonesian Automotive Industry. Bulletin of Indonesian Economic Studies, [e-journal] 51(1), pp.47-68. DOI: 10.1080/00074918.2015.1016567.
Paramawardhani, H. and Amar, K., 2020. Waste Identification in Production Process Using Lean Manufacturing: A Case Study. Journal of Industrial Engineering and Halal Industries, 1(1), pp.39-46.
Prabowo, H.A. and Adesta, E.Y.T., 2019. A study of total productive maintenance (TPM) and lean manufacturing tools and their impact on manufacturing performance. International Journal of Recent Technology and Engineering, 7(6), pp.39-43.
Prayugo, J. and Zhong, L.X., 2021. Green productivity: waste reduction with green value stream mapping. A case study of leather production. International Journal of Production Management and Engineering, [e-journal]9(1), pp.47-55. DOI: 10.4995/ijpme.2021.12254.
Psomas, E. and Antony, J., 2019. Research gaps in Lean manufacturing: a systematic literature review. International Journal of Quality and Reliability Management, [e-journal] 36(5), pp.815-839. DOI: 10.1108/IJQRM-12-2017-0260.
Rifqi, H., Zamma, A., Souda, S.B. and Hansali, M., 2021. Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry. Quality Innovation Prosperity, [e-journal] 25(2), pp.54-77. DOI: 10.12776/QIP.V25I2.1576.
Rizkya, I., Syahputri, K., Sari, M.R. and Situmorang, S.D., 2020. Lean Manufacturing: Waste Analysis in Crude Palm Oil Process Lean Manufacturing: Waste Analysis in Crude Palm Oil Process. ITEM, IOP Conference Series Materials Science and Engineering ITEM 2020. Batam, Indonesia, 02-04 April 2020. IOP Publishing. pp.1-8. DOI: 10.1088/1757-899X/851/1/012058.
Romero, L.F. and Arce, A., 2017. Applying Value Stream Mapping in Manufacturing: A Systematic Literature Review. IFAC-PapersOnLine, [e-journal] 50(1), pp.1075-1086. DOI: 10.1016/j.ifacol.2017.08.385.
Seth, D., Seth, N. and Dhariwal, P., 2017. The Management of Operations Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study. Production Planning & Control, [e-journal] 7287(5), pp.398-419. DOI: 10.1080/09537287.2017.1300352.
Setiawan, I., Tumanggor, O.S.P. and Purba, H.H., 2021. Value Stream Mapping: Literature Review and Implications for Service Industry. Jurnal Sistem Teknik Industri, [e-journal] 23(2), pp.155-166. DOI: 10.32734/jsti.v23i2.6038.
Setiawan, L. and Hasibuan, S., 2021. Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing. Quality Innovation Prosperity, [e-journal] 25(2), pp.19-36. DOI: 10.12776/qip.v25i2.1516.
Siregar, I., Nasution, A.A., Andayani, U., Sari, R.M., Syahputri, K. and Anizar, 2018. Lean manufacturing analysis to reduce waste on production process of fan products. IOP Conference Series: Materials Science and Engineering, [e-journal] 308, pp.1-8. DOI: 10.1088/1757-899X/308/1/012004.
Swarnakar, V. and Vinodh, S., 2016. Deploying Lean Six Sigma framework in an automotive component manufacturing organization. International Journal of Lean Six Sigma, [e-journal] 7(3), pp.267-293. DOI: 10.1108/IJLSS-06-2015-0023.
Syah, D.O., 2019. Identifying vertical partnership among automotive component companies: empirical evidence from automotive industry in Jabodetabek, Indonesia. Journal of Economic Structures, [e-journal] 8(33), pp.1-25. DOI: 10.1186/s40008-019-0149-z.
Tannady, H., Gunawan, E., Nurprihatin, F. and Wilujeng, F.R., 2019. Process improvement to reduce waste in the biggest instant noodle manufacturing company in South East Asia. Journal of Applied Engineering Science, 17(2), pp.203-212. DOI: 10.5937/jaes17-18951.
Tortorella, G., Sawhney, R., Jurburg, D., de Paula, I.C., Tlapa, D. and Thurer, M., 2021. Towards the proposition of a Lean Automation framework: Integrating Industry 4.0 into Lean Production. Journal of Manufacturing Technology Management, [e-journal] 32(3), pp.593-620. DOI: 10.1108/JMTM-01-2019-0032.
Tortorella, G.L., Narayanamurthy, G. and Thurer, M., 2021. Identifying pathways to a high-performing lean automation implementation: An empirical study in the manufacturing industry. International Journal of Production Economics, [e-journal] 231, 107918. DOI: 10.1016/j.ijpe.2020.107918.
Zahrotun, N. and Taufiq, I., 2018. Lean Manufacturing: Waste Reduction Using Value Stream Mapping. E3S Web of Conferences, [e-journal] 73(1), pp.2-7. DOI: 10.1051/e3sconf/20187307010.
Chaurasia, B., Garg, D. and Agarwal, A., 2019. Lean Six Sigma approach: a strategy to enhance performance of first through time and scrap reduction in an automotive industry. International Journal Business Excellence, 17(1), pp.42-57. DOI: 10.1504/IJBEX.2019.096903.
Dănuţ-Sorin, I.R., Opran, C.G. and Lamanna, G., 2020. Lean Manufacturing 4.0 of Polymeric Injection Molding Products. Macromolecular Symposia, [e-journal] 389(1), pp.10-12. DOI: 10.1002/masy.201900109.
Garza-reyes, J.A., Sebastian, J., Forero, B., Kumar, V., Cedillo-campos, M.G. and Rocha-lona, L., 2017. Improving Road Transport Operations using Lean Thinking. Procedia Manufacturing, [e-journal] 11(June), pp.1900-1907. DOI: 10.1016/j.promfg.2017.07.332.
Habidin, N.F., Salleh, M.I., Latip, N.A. and Nor, M., 2016. Lean six sigma performance improvement tool for automotive suppliers. Journal of Industrial and Production Engineering, [e-journal] 33(4), pp.215-235. DOI: 10.1080/21681015.2015.1136966.
Henny, H. and Budiman, H.R., 2018. Implementation lean manufacturing using Waste Assessment Model (WAM) in shoes company. IOP Conference Series: Materials Science and Engineering, [e-journal] 407(1), pp.1-6. DOI: 10.1088/1757-899X/407/1/012077.
Ikatrinasari, Z.F., Hasibuan, S. and Kosasih, K., 2018. The Implementation Lean and Green Manufacturing through Sustainable Value Stream Mapping. International Conference on Design, Engineering and Computer Sciences, 453(1), pp.1-9. DOI: 10.1088/1757-899X/453/1/012004.
Irawati, D. and Charles, D., 2010. The involvement of Japanese MNEs in the Indonesian automotive cluster. International Journal Automotive Technology and Management, 10(2), pp.180-196. DOI:10.1504/IJATM.2010.032623.
Kaneku-Orbegozo, J., Martinez-Palomino, J., Sotelo-Raffo, F. and Ramos-Palomino, E., 2019. Applying Lean Manufacturing Principles to reduce waste and improve process in a manufacturer: A research study in Peru. IOP Conference Series: Materials Science and Engineering, [e-journal] 689(1), pp.1-7. DOI: 10.1088/1757-899X/689/1/012020.
Lacerda, A.P., Xambre, A.R. and Alvelos, H.M., 2016. Applying Value Stream Mapping to eliminate waste: A case study of an original equipment manufacturer for the automotive industry. International Journal of Production Research, [e-journal] 54(6), pp.1708-1720. DOI: 10.1080/00207543.2015.1055349.
Leksic, I., Stefanic, N. and Veza, I., 2020. The impact of using different lean manufacturing tools on waste reduction. Advances in Production Engineering & Management, [e-journal] 15(1), pp.81-92. DOI: 10.14743/apem2020.1.351.
Liker, J.K. and Meier, D., 2006. The Toyota Way Fieldbook - A Practical Guide for Implementing Toyota’s 4Ps. New York. McGraw-Hill.
Marifa, P.C., Andriani, F.Y., Indrawati, S., Parmasari, A.N., Budiman, H. and Kamilia, A., 2018. Production waste analysis using value stream mapping and waste assessment model in a handwritten batik industry. MATEC Web of Conferences, [e-journal] 154, pp.10-13. DOI: 10.1051/matecconf/201815401076.
Nallusamy, S. and Adil Ahamed, M.A., 2017. Implementation of lean tools in an automotive industry for productivity enhancement - A case study. International Journal of Engineering Research in Africa, [e-journal] 29(1), pp.175-185. DOI: 10.4028/www.scientific.net/JERA.29.175.
Narkea, M. and Jayadevab, C.T., 2020. Value Stream Mapping: Effective Lean Tool for SMEs. International Conference on Advances in Materials and Manufacturing Applications, [e-journal] 24(2), pp.1263-1272. DOI: 10.1016/j.matpr.2020.04.441.
Natsuda, K., Otsuka, K. and Thoburn, J., 2015. Dawn of Industrialisation? The Indonesian Automotive Industry. Bulletin of Indonesian Economic Studies, [e-journal] 51(1), pp.47-68. DOI: 10.1080/00074918.2015.1016567.
Paramawardhani, H. and Amar, K., 2020. Waste Identification in Production Process Using Lean Manufacturing: A Case Study. Journal of Industrial Engineering and Halal Industries, 1(1), pp.39-46.
Prabowo, H.A. and Adesta, E.Y.T., 2019. A study of total productive maintenance (TPM) and lean manufacturing tools and their impact on manufacturing performance. International Journal of Recent Technology and Engineering, 7(6), pp.39-43.
Prayugo, J. and Zhong, L.X., 2021. Green productivity: waste reduction with green value stream mapping. A case study of leather production. International Journal of Production Management and Engineering, [e-journal]9(1), pp.47-55. DOI: 10.4995/ijpme.2021.12254.
Psomas, E. and Antony, J., 2019. Research gaps in Lean manufacturing: a systematic literature review. International Journal of Quality and Reliability Management, [e-journal] 36(5), pp.815-839. DOI: 10.1108/IJQRM-12-2017-0260.
Rifqi, H., Zamma, A., Souda, S.B. and Hansali, M., 2021. Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry. Quality Innovation Prosperity, [e-journal] 25(2), pp.54-77. DOI: 10.12776/QIP.V25I2.1576.
Rizkya, I., Syahputri, K., Sari, M.R. and Situmorang, S.D., 2020. Lean Manufacturing: Waste Analysis in Crude Palm Oil Process Lean Manufacturing: Waste Analysis in Crude Palm Oil Process. ITEM, IOP Conference Series Materials Science and Engineering ITEM 2020. Batam, Indonesia, 02-04 April 2020. IOP Publishing. pp.1-8. DOI: 10.1088/1757-899X/851/1/012058.
Romero, L.F. and Arce, A., 2017. Applying Value Stream Mapping in Manufacturing: A Systematic Literature Review. IFAC-PapersOnLine, [e-journal] 50(1), pp.1075-1086. DOI: 10.1016/j.ifacol.2017.08.385.
Seth, D., Seth, N. and Dhariwal, P., 2017. The Management of Operations Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study. Production Planning & Control, [e-journal] 7287(5), pp.398-419. DOI: 10.1080/09537287.2017.1300352.
Setiawan, I., Tumanggor, O.S.P. and Purba, H.H., 2021. Value Stream Mapping: Literature Review and Implications for Service Industry. Jurnal Sistem Teknik Industri, [e-journal] 23(2), pp.155-166. DOI: 10.32734/jsti.v23i2.6038.
Setiawan, L. and Hasibuan, S., 2021. Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing. Quality Innovation Prosperity, [e-journal] 25(2), pp.19-36. DOI: 10.12776/qip.v25i2.1516.
Siregar, I., Nasution, A.A., Andayani, U., Sari, R.M., Syahputri, K. and Anizar, 2018. Lean manufacturing analysis to reduce waste on production process of fan products. IOP Conference Series: Materials Science and Engineering, [e-journal] 308, pp.1-8. DOI: 10.1088/1757-899X/308/1/012004.
Swarnakar, V. and Vinodh, S., 2016. Deploying Lean Six Sigma framework in an automotive component manufacturing organization. International Journal of Lean Six Sigma, [e-journal] 7(3), pp.267-293. DOI: 10.1108/IJLSS-06-2015-0023.
Syah, D.O., 2019. Identifying vertical partnership among automotive component companies: empirical evidence from automotive industry in Jabodetabek, Indonesia. Journal of Economic Structures, [e-journal] 8(33), pp.1-25. DOI: 10.1186/s40008-019-0149-z.
Tannady, H., Gunawan, E., Nurprihatin, F. and Wilujeng, F.R., 2019. Process improvement to reduce waste in the biggest instant noodle manufacturing company in South East Asia. Journal of Applied Engineering Science, 17(2), pp.203-212. DOI: 10.5937/jaes17-18951.
Tortorella, G., Sawhney, R., Jurburg, D., de Paula, I.C., Tlapa, D. and Thurer, M., 2021. Towards the proposition of a Lean Automation framework: Integrating Industry 4.0 into Lean Production. Journal of Manufacturing Technology Management, [e-journal] 32(3), pp.593-620. DOI: 10.1108/JMTM-01-2019-0032.
Tortorella, G.L., Narayanamurthy, G. and Thurer, M., 2021. Identifying pathways to a high-performing lean automation implementation: An empirical study in the manufacturing industry. International Journal of Production Economics, [e-journal] 231, 107918. DOI: 10.1016/j.ijpe.2020.107918.
Zahrotun, N. and Taufiq, I., 2018. Lean Manufacturing: Waste Reduction Using Value Stream Mapping. E3S Web of Conferences, [e-journal] 73(1), pp.2-7. DOI: 10.1051/e3sconf/20187307010.
Authors
Setiawan, S., Setiawan, I. ., Jaqin, C. ., Prabowo, H. A. ., & Purba, H. H. . (2021). Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry. Quality Innovation Prosperity, 25(3), 48–64. https://doi.org/10.12776/qip.v25i3.1613
This work is licensed under a Creative Commons Attribution 4.0 International License.