Title: Waste analysis on the production floor and proposed improvements using a lean manufacturing approach aluminium manufacturing company in East Java, Indonesia

Authors: Moch Anshori; Suparno; Donny Arif

Addresses: Faculty of Engineering, Maarif Hasyim Latif University, Sidoarjo, Indonesia ' Sepuluh Nopember Institute of Technology, Surabaya, Indonesia ' Faculty of Economics and Business, Maarif Hasyim Latif University, Sidoarjo, Indonesia

Abstract: This study aims to analyse waste on the production floor, causing delays in the completion of the production process and affecting product delivery to consumers. In addition, this research is also used to explain the types of waste and provide alternative improvements to reduce waste on the production floor using a lean manufacturing approach. Using the value stream mapping method, researchers mapped the flow of information and materials in the production process. Furthermore, the actual condition of the company is described in the current state stream map using the 5W-1H method of waste identification tool. This study found that there were a waste of defective goods in the frame, wastage in the weaving repair process and activities to find boxes and waste of transportation on the production floor. Implementing the proposed improvement is expected to reduce the waste that occurs to reduce the production lead time.

Keywords: waste production floor; lean manufacturing; aluminium manufacturing; value stream mapping; Indonesia.

DOI: 10.1504/IJPMB.2025.143614

International Journal of Process Management and Benchmarking, 2025 Vol.19 No.1, pp.131 - 146

Received: 07 Jan 2023
Accepted: 25 Jan 2023
Published online: 02 Jan 2025 *

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