Evaluation of Local Management System towards Application of Kaizen to Increase Productivity in the Precast Production Process

PT. Merak Jaya Pracetak is one of the largest precast concrete industries in East Java, where to realize this vision, the company continues to develop products and increase productivity by improving service quality, production processes and product delivery to customers with minimum costs and the right delivery time. To achieve that goal, a kaizen method is needed to eliminate 3M (muda, mura, and muri) and manage activities that do not add value to the production process. Research begins with a description of the company using field observations. Waste was analyzed by questionnaires and check sheets, then analyzed with Pareto diagrams, then analyzed for causal analysis with five reasons for analysis and analyzed with fish bone diagrams. Next, do an evaluation using this brainstorming to improve and do the last with 5R or 5S in the work area. The results showed that 3M was the most critical which affected inventory productivity (29.00%), movement (19.00%), and transportation (17.00%). The effect of implementing kaizen in increasing savings, the presence of time savings in your production process u-ditch 800mm x 1000mm x 1200mm (t = 10cm) as many as 12 units amounting to 6000.90 seconds (100 minutes) or around (18.69%) and production processes square pile 20cm x 20cm x 4m as many as 120 units amounting to 7298.48 seconds (121 minutes) or around (18.61%)