OPTIMALISASI LINI PRODUKSI PADA PRODUK EJ0078 DENGAN VSM (VALUE STREAM MAPPING) DAN METODE ERCS-BASED LINE BALANCING (ELIMINATE, COMBINE, REARRANGE, SIMPLIFY) DI PT. XYZ, SURABAYA

Abstract

PT XYZ has received an order  for  kick gear product EJ00078 that exceeds  current production capacity. Therefore, production line improvements are required to address this problem and meet order demands. One of the main focuses for maximizing production capacity is to use value stream mapping techniques and ECRS (Eliminate, Combine, Relocate, Simplify) integration to identify waste and find the optimal solution to improve production results. It's about finding solutions. Value  stream mapping identified a bottleneck  in the bevel process that took 5 seconds, compared to only 2.5 seconds for other processes. This resulted in wasted time  and increased wait times for products to be processed. Redesigning the touch station has streamlined the production process, reducing the time required for touch operations to 2.5 seconds,  the same as other workstations. To minimize waste, further identification of waste was performed using the ECRS method. This includes the reorganization of the production area for EJ00078 units, the elimination and consolidation of the inspection process at each final workstation  before the packing process for EJ00078 units. The testing process was simplified and expedited as automated testing was already in place at each workplace. The final final inspection  only confirms that the product meets the prescribed standards.