Lean Manufacturing: Menurunkan Work In Process di Cell Prismatic (Studi Kasus di PT Aerospace Indonesia)

Abstract

PT Aerospace Indonesia is an aerospace manufacturing company located in Bandung. The main issue faced by the company is the high level of Work In Process (WIP), particularly for components produced in the prismatic cell, which ranks first by accounting for 45% of the total WIP distribution at PT Aerospace Indonesia. The THSA (Trimmable Horizontal Stabilizer Actuator) component also ranks first within the prismatic cell, comprising 21% of the WIP distribution in that area. This study aims to reduce the WIP of the THSA component and analyze the contributing factors to its high WIP levels. The methodology employed involves a lean manufacturing approach using tools such as Production Activity Mapping (PAM), Value Stream Mapping (VSM), and Kaizen. Lean manufacturing was selected as the solution because it is specifically designed to identify and eliminate waste in production processes, including excessive WIP accumulation. A Pilot Test method was used to implement improvement solutions in a limited and controlled area to evaluate their effectiveness, identify potential obstacles, and collect comparative data before and after implementation.The results of the pilot test showed that WIP was successfully reduced from 180 pcs to 55 pcs. This reduction in WIP led to improved smoother material flow.