Reduce waste using VALSAT and FMEA approach in welding under body process

• Main Authors: Kholil, Muhammad, Koeswara, Sonny, Hidayat, Atep Afia, Haekal, Jakfat
• Format: Conference Proceeding
• Language: English
• Subjects: Assembling; Efficiency; Failure modes; Iron; Pallets; Root cause analysis; Underbodies; Welding
• ISSN: 0094-243X; 1551-7616
• DOI: 10.1063/5.0223508

To increase competitiveness with its competitors at the national, regional, and global levels, The Manufacturing company in this research improves the efficiency of the production process. However, the efficiency in welding did not reach the target. From the target of 97%, the actual efficiency was 95.9%. The late process dominates Line Stop by 1.7%. The late process is a strong indication of waste. The research was conducted using the Value Stream Analysis Tools (VALSAT) method, and it was found that there were 3 critical wastes, including motion 24.4%, overproduction 18.5%, and inventory 15.8%. With the Root Cause Analysis (RCA) method combined with Failure Mode and Effect Analysis (FMEA), 4 priority scales of root causes are obtained, namely: Medium part assembling system is carried out manually, the Storage system (packing style part) using iron pallets, Production system using big lot system, and the number of parts placement containers reach 800 units. The countermeasures are making a full auto hanger, changing the packing style from iron pallets to poly boxes and dollies, changing the production system to a small lot system, and making dolly common (1 dolly to install 8 part variants). By comparing the Value Stream Mapping conditions before and after, the final results are: 178 minutes of working time reduction, 58 activities reduction, 2 forklift usage reduction, and 2,306 m2 of keeping space. So that it can increase the efficiency of the underbody assembly process from 95.9% to 98.4%. This research supports the company policy in terms of increasing the company’s competitiveness at the national, regional, and global levels. One of the improvements in this research is direct supply using dolly common, a benchmark item for Toyota affiliates in the Asia Pacific.