Observing the Effectivenss of Lean Manufacturing Tools Applied in the GPC Printing PT 3M Indonesia

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"Knowledge without observation is nil"

Mustaman, Bambang S. and Hendayana, Jajang Y. (2011) Observing the Effectivenss of Lean Manufacturing Tools Applied in the GPC Printing PT 3M Indonesia. Project Report. Sekolah Tinggi Manajemen IPMI, Jakarta Selatan. (Unpublished)

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The Manufacturing and Engineering Department of PT 3M Indonesia is conducting an evaluation, expansion and development of its manufacturing processes, and so for such purposes will be addressed in the process efficiency, reducing process lead time, and cost saving through manufacturing efficiency from the starting of production until the arriving in the hands of its customers. The intention of this group field project is to observe and to consider that the application and the implementation of lean manufacturing especially in the GPC printing division of PT 3M Indonesia, whether it is considered effective. In general, the expectation will be more simple processes but a thorough, efficient processes with pull systems and single pieces flow, and processes with more time-efficient, which in turn will automatically save costs and thus, can significantly increase net profits of the company. In relation to doing this project, all data and information from the GPC printing division have been collected and analyzed. The analysis was conducted to provide some classifications and clustering items to check the sales order volume, whether it is easily forecasted or difficult to be forecasted. The monthly order from the major customer is quite stable during a year. Further consideration are provided with ABC classifications, Volatility in Demand patterns analysis with Back testing analysis, Mean average percentage error or MAPE calculation and Pareto analysis. The expected results of success are in line with the requirements and expectations of the management of Manufacturing and Engineering of PT 3M Indonesia. Cost saving was a subject which has been chosen as the most important measurement in determining the effectiveness of the lean tools that have been applied in the manufacturing division. Through the Analytical Hierarchy Process analysis, it has been shown that the highest decision score value is in accordance with what has been implemented in the current lean manufacturing and production strategy, namely the pull system or single pieces flow. After that followed by the value stream mapping technique and the best lay out or work cell for the production flow, then by the built in quality, 5S implementation and reducing setup time which are the basis of improvement in production processes. To summarize, it can be stated that the application and implementation of lean manufacturing in PT 3M Indonesia can be considered effective. The main recommendation for PT 3M Indonesia is to continue deploying lean manufacturing programs with current techniques that have been implemented. This program has been reviewed in certain periods of 6 months or 1 year and the effectiveness has been analyzed by empirical and or historical data, i.e. inventory reduction, productivity per man hour, and quality defect reduction. In addition, another suggestion is to develop Cost and Benefit analysis based on real internal data in order to know exactly the competitive benefits of this lean program for the company. Finally, it would be very useful to develop training programs, build learning and continue culture improvement in the whole organization which is in line with the lean spirit to grow and respect people, and also to build the bottom-up problem solving culture. Keywords: Forecasting Customer Demand, Inventory Control, Production Scheduling and Strategy, Single Piece Flow, Value Stream Mapping, Re-laying out or Work-cell, Build-in Quality, 5S Implementation, Reducing Set-up Time, and Analytical Hierarchy Process.

Item Type: Monograph (Project Report)
Subjects: H Social Sciences > H Social Sciences (General)
H Social Sciences > HD Industries. Land use. Labor
Divisions: Library > GFP (Group Field Project)
Depositing User: Putri Lumithasari
Date Deposited: 22 Jan 2020 03:11
Last Modified: 22 Jan 2020 03:11
URI: http://repository.ipmi.ac.id/id/eprint/531

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