Pical, Ariel Julianus and Irawati, Desrina Yusi and Andrian, David (2025) Lean Manufacturing Analysis: Using WAM and VALSAT to Reduce Waste in the Plastic Sack Finishing Process at PT Surya Plastindo. Engineering Headway, 18. pp. 153-162. ISSN 2813-8333
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Abstract
PT Surya Plastindo is a company that produces plastic sacks. The finishing workstation
often encounters various issues, including an excessive number of defective printed products and
production quantities consistently exceeding order specifications. This study aims to eliminate waste
and implement improvements in the finishing workstation. The lean manufacturing method is suitable
for reducing waste at PT Surya Plastindo. The waste elimination process begins with describing the
production flow and calculating cycle times for each process, using Value Stream Mapping (VSM)
to depict the current state. Subsequently, the Waste Assessment Model (WAM) is employed to weight
and rank critical waste. The most critical wastes are further analyzed using value stream mapping
tools, with the VALSAT tool selected to map the value flow during production. Finally, a five-why
analysis is performed to recommend improvements. According to WAM’s waste weighting
calculations, defects (20.76%), motion (18.32%), and overproduction (17.54%) are identified as the
most significant wastes. The analysis, combined with discussions with production heads and detailed
mapping using VALSAT tools, resulted in three recommendations for improvement: the creation of
daily production cards, checklists for printing machines, and plastic sack supports for the printing
machines. The implementation of these improvements resulted in a reduction in delays and increased
efficiency in plastic sack production.
| Item Type: | Article |
|---|---|
| Uncontrolled Keywords: | Lean Manufacturing; Waste; WAM; VSM; VALSAT |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management T Technology > T Technology (General) T Technology > TS Manufactures |
| Divisions: | Fakultas Teknik > Prodi Teknik Industri |
| Depositing User: | Desrina Yusi Irawati |
| Date Deposited: | 04 Jul 2025 11:57 |
| Last Modified: | 07 Jul 2025 07:24 |
| URI: | https://repositori.ukdc.ac.id/id/eprint/2338 |
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