ABSTRAKSI: KATA KUNCI: ABSTRACT: PT. Nikattsu Eletrics Works is a national private company that produces power tools and energy saving lamps that are established to fullfil the needs of users. One of its products whose demand is the biggest on 2013 is Trafo ballast ekspor. To fullfil the demand, the company decides the target to be 100%. The demand is up to 9.340 products on a day, but it can only fulfill 7.385 products with a machine capacity of 46.410 products per day.. The unreachable target happened is caused by the wastes in Trafo ballast ekspor production. The waste weighting is done and got the second biggest waste is waste waiting that affect the unreachable company’s product target.
The research phases are started with making a current state map, it is done to identify the material and information flow in the Trafo ballast ekspor production line and obtained that the value added time is 1.083,127 seconds and the lead time is 2.262,427 seconds. If the machine is breaking down for a day then the lead time value will be 6.402,427 seconds. The next phase is making the process activity mapping to get the detail mapping and the percentage of the activity, those are value added time 47%, necessary non value added time 31% and non-value time 23%.
The research is continued by doing the calculation of the overall equipment effectiveness value to get the effectivity of each Trafo ballast ekspor production machine. The OEE calculation shows the Availability value 94%, performance 81% and quality 81% with the total of OEE 75%. It shows that the improvement of actual production time and planned production time is needed to increase the Performance Efficiency value. It is continued by calculate the six big losses value from each machine and got the biggest losses value and that will be the improvement priority is reduced speed by 83.80%. The causes of reduced speed waste of Trafo ballast ekspor are the machine jammed, the spareParts are napless, the limit of employees’ skill and amount, the fault of machine setup (calibration) and the preventive maintenance activities that are not optimal yet, causes the damage to the machine. The final phase is giving the proposal to overcome the happened problems based on the problem identification using the fishbone and 5 Why’s.
KEYWORD: Fishbone chart, Lean manufacturing,Overall effectiveness equipment, VSM,waste waiting, Six big losses,5 Why