ANALYSIS OF WASTE ON THE PRODUCTION FLOOR WITH LEAN MANUFACTURING METHOD

In defending his company's existence, many ways in which an enterprise so that the results of his efforts remains in demand by consumers. The desire of consumers or the so-called voice of customer is very complex; making the company should give priority to customers above anything else. it aims to keep consumers loyal to the products it makes. PT. Dianjaya Gunawan Steel (GDS) is one of the major companies producing steel plate in Indonesia which has the International level. The company is constantly improving product quality and constantly striving to meet customer desires. But in the process of production of steel plate ABS type-A (12x1524x6096) mm there are still obstacles faced. factor constraints faced by the company so much that it makes less maximum production runs. For example, the waste found on the production floor, resulting in losses to the company. In this study, researchers tried to analyze the activities that are categorized as non-value added. Therefore we need a method to identify the overall waste by using Lean Manufacturing through a VSM (Value Stream Mapping) Tool, where the selection of his own tools using VALSAT (Value Stream Analysis Tools) in hopes of reducing the waste that occurs. Based on the survey results revealed that of making BPM (Big Picture Mapping), types of waste are successfully identified with BPM is Waiting, Unnecessary Inventory, and Overproduction. Also used are also RCA (Root Cause Analysis) to identify the waste, other waste. To minimize the waste that has been identified is given some of the proposed improvements, such as changing the company policy in preparation a cutting slab, can reduce the waiting in the preparation area of cutting slab from 10,080 minutes (7 days) to 420 minutes (0.29 days).. change company policy in the process of a cutting slab, can reduce the waiting area of a cutting slab of 4752 minutes (3.3 days) to 272 minutes (0.19 days) and suppress the overproduction of 594 pieces to 34 pieces of slab, while also reducing unnecessary inventory of 17.5 days to 1.9 days. And having analyzed the results of the proposed improvements can significantly reduce production lead time is initially 14 952 minutes (10.39 days) to 812 minutes (0.56 days)