ANALYSIS OF PRODUCTION PROCESS OF ELECTRONIC TRANSFORMER BY LEAN SIX SIGMA AND TRIZ Adritho Zaifar
Institut Teknologi Sepuluh Nopember Surabaya
Jl. Cokroaminoto No.12A, DR. Soetomo, Kec. Tegalsari, Kota SBY, Jawa Timur 60264
INTERDICIPLINARY SCHOOL OF MANAGEMENT TECHNOLOGY
Abstract
PT X is one of Indonesia^s main manufacturers and distributors of electronic transformers. The company has struggled to keep up with the increased quantity and quality demanded by customers. At the same time, the company wants to minimize non-value-added activities in the production process. This research aims to identify the main factors of the transformer production process to improve the efficiency and quality of the electronic transformers produced. This research uses Lean Six Sigma and Cause Analysis to identify waste in the production process that causes long lead times and lower quality standards. The TRIZ methodology will support process improvement efforts if the improvement resulting from the Lean Six Sigma method produces contradictions. The data that will be used is data on the production flow of electronic transformers from start to finish and data on group discussions. The result of the studies found that if PT. X eliminates non-value-added activities through automation, the investment that the company made in these technologies is deemed profitable as the NPV calculation result is a positive Rp. 43,181,818. The result of this automation will also enable PT. X to reduce the number of its labour which resulting a cost saving of around 54% of its labour cost in which if converted into monetary value will be Rp. 68,255,748 in financial savings.
Keywords: Root Cause Analysis, TRIZ, Focus Group Discussion (FGD), Lean Six Sigma, Productivity, and Quality Improvement
