Increased line efficiency by improved work methods with the ECRS concept in a washing machine production: a case study

Authors

  • Asariella Findya Octa Pertiwi Universitas Sebelas Maret
  • Rahmaniyah Dwi Astuti Universitas Sebelas Maret

DOI:

https://doi.org/10.30656/jsmi.v4i1.2184

Keywords:

Work method, ECRS, Manufacturing, Productivity, Line efficiency

Abstract

The Assembly line is the assembly process that is carried out based on the order of the production process in the production line. The problem that is often found in assembly lines is bottleneck conditions where some material piled up at the station. This situation indicates an imbalance in the production line. The improvement of the work method is one of the effective ways that can increase line efficiency. This study presents an increase in line efficiency by improving working methods in a washing machine assembly line of PT.X. The study aimed to increase the value of line efficiency by improving work methods. In this study, improvements were made using the line balancing method and Eliminate, Combine, Rearrange, Simplify (ECRS) concept. The results that have been done, the obtained value of line efficiency for washing machine products is 76.76%. This value has not reached the company's productivity target of 99.50%. Therefore it is necessary to improve the assembling line to increase the value of product production. The proposed improvements made with improvements to the work methods on the assembling line obtained 89.38% results is to increase the amount of line efficiency by improving work methods.

References

A. D. Makwana and G. S. Patange, “Strategic implementation of 5S and its effect on productivity of plastic machinery manufacturing company,†Aust. J. Mech. Eng., pp. 1–10, Oct. 2019.

Ashish Kalra, Sachin Marwah, Sandeep Srivastava, and Rajesh Bhatia, “Productivity Improvement in Assembly Line of Automobile Industry by Reducing Cycle time of Operations,†Int. J. Eng. Res., vol. 5, no. 05, pp. 28–31, May 2016.

A. Jaggi, S. Patra, and D. S. Chaubey, “Application of line-balancing to minimize the Idle time of workstations in the production line with special reference to automobile industry,†Int. J. IT, Eng. Appl. Sci. Res., vol. 4, no. 7, pp. 8–12, 2015.

D. Battini, X. Delorme, A. Dolgui, A. Persona, and F. Sgarbossa, “Ergonomics in assembly line balancing based on energy expenditure: a multi-objective model,†Int. J. Prod. Res., vol. 54, no. 3, pp. 824–845, Feb. 2016.

R. Rahayu, “Pengaruh Aplikasi Strategi Just In Time Terhadap Efektivitas dan Efisiensi Biaya Produksi Pada PT. Santosa Jaya Abadi Sidoarjo,†EKUITAS (Jurnal Ekon. dan Keuangan), vol. 9, no. 4, pp. 439–463, 2018.

N. T. Lam, L. M. Toi, V. T. T. Tuyen, and D. N. Hien, “Lean Line Balancing for an Electronics Assembly Line,†Procedia CIRP, vol. 40, no. 1, pp. 437–442, 2016.

L. Botti, C. Mora, and A. Regattieri, “Integrating ergonomics and lean manufacturing principles in a hybrid assembly line,†Comput. Ind. Eng., vol. 111, no. 5, pp. 481–491, Sep. 2017.

R. Soesilo, “Meningkatkan Output Dengan Melakukan Perubahan Tata Letak di Area Produksi,†J. Ind. Eng. Manag., vol. 2, no. 2, pp. 23–31, Dec. 2017.

R. M. Yusuff and N. S. Abdullah, “Ergonomics as a lean manufacturing tool for improvements in a manufacturing company,†in Proceedings of the International Conference on Industrial Engineering and Operations Management, 2016, pp. 581–588.

M.-N. Nguyen and N.-H. Do, “Re-engineering Assembly Line with Lean Techniques,†Procedia CIRP, vol. 40, pp. 590–595, 2016.

J. Dinis-Carvalho, L. Guimaraes, R. M. Sousa, and C. P. Leao, “Waste identification diagram and value stream mapping,†Int. J. Lean Six Sigma, vol. 10, no. 3, pp. 767–783, Aug. 2019.

P. Srinivasa Rao and M. Niraj, “A case study on implementing lean ergonomic manufacturing systems (LEMS) in an automobile industry,†IOP Conf. Ser. Mater. Sci. Eng., vol. 149, pp. 1–9, Sep. 2016.

I. Alsaffar and H. Ketan, “Reviewing the Effects of Integrated Lean Six Sigma Methodologies with Ergonomics Principles in an Industrial Workstation,†IOP Conf. Ser. Mater. Sci. Eng., vol. 433, no. 1, pp. 1–13, Nov. 2018.

A. N. M. Amin, W. H. W. Mahmood, S. R. Kamat, and I. Abdullah, “Conceptual framework of lean ergonomics for assembly process: PDCA approach,†J. Eng. Sci. Res., vol. 2, no. 1, pp. 51–62, 2018.

R. Khani Jazani, A. Salehi Sahlabadi, and S. S. Mousavi, “Relationship Between Lean Manufacturing and Ergonomics,†in International Conference on Applied Human Factors and Ergonomics, Springer, 2018, pp. 162–166.

H. Murnawan, “Perencanaan Produktivitas Kerja Dari Hasil Evaluasi Produktivitas Dengan Metode Fishbone Di Perusahaan Percetakan Kemasan Pt. X,†HEURISTIC J. Tek. Ind., vol. 11, no. 01, pp. 27–46, 2014.

M. I. Fajrianto, T. G. Amran, and N. Azmi, “Rancang Bangun Model Lean Productivity Dengan Pendekatan Objective Matrix - Value Stream Mapping - ECRS (Studi Kasus: PT. X),†J. Tek. Ind., vol. 5, no. 3, pp. 61–72, 2017.

B. Suhardi, N. Anisa, and P. W. Laksono, “Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry,†Cogent Eng., vol. 6, no. 1, pp. 1–13, Jan. 2019.

C. Kasemset, C. Boonmee, and P. Khuntaporn, “Application of MFCA and ECRS in waste reduction: A case study of electronic parts factory,†in Proceedings of the 2016 International Conference on Industrial Engineering and Operations Management, 2016, pp. 1844–1853.

I. N. Fadlil and C. N. Rosyidi, “Improvement of work processes and methods to achieve production targets using VA/NVA analysis, ECRS and line balancing,†in AIP Conference Proceedings, 2020, vol. 2217, no. 1, pp. 1–10.

G. J. Pawar, N. S. Sirdeshpande, A. B. Atram, and P. R. Patil, “Reduction in setup change time of a machine in a bearing manufacturing plant using SMED and ECRS,†Int. J. Eng. Res., vol. 3, no. 5, pp. 321–323, May 2014.

T. G. Amran and N. C. Wibowo, “Perbaikan Proses Produksi Sistem Pengereman Kendaraan Bermotor Dengan Metode ECRS-Based Line Balancing,†in Prosiding Seminar Nasional Pakar, 2018, pp. 193–204.

Y. Indrawan and N. L. P. Hariastuti, “Minimalisasi bottleneck proses produksi dengan menggunakan metode line balancing,†Jur. Tek. Ind. Inst. Teknol. Adhi Tama Surabaya, vol. 6, no. 1, pp. 1–10, 2014.

V. F. Daelima, E. Febianti, and M. A. Ilhami, “Analisis Keseimbangan Lintasan untuk Meningkatkan Kapasitas Produksi dengan Pendekatan Line Balancing dan Simulasi,†J. Tek. Ind. Untirta, vol. 1, no. 2, pp. 107–113, 2013.

H. Sofyan, M. Nadeak, and T. B. Prasetyo, “Peningkatan Produktivitas pada Proses Assembling Priming Set Melalui Perbaikan Stasiun Kerja Menggunakan Metode Time Study,†J. Ilm. Trendtech, vol. 3, no. 1, pp. 38–44, 2018.

D. Pujotomo and D. N. Rusanti, “Usulan Perbaikan Untuk Meningkatkan Produktivitas Fillingplant Dengan Pendekatan Lean Manufacturing Pada PT. Smart Tbk Surabaya,†J@TI UNDIP J. Tek. Ind., vol. 10, no. 2, pp. 123–132, Jun. 2015.

M. B. Ralph, Motion and Time Study Design and Measurement of Work. 7th ed. Singapore: John Wiley & Sons, 1980.

H. Purnomo, Pengantar Teknik Industri. Yogyakarta: Graha Ilmu, 2004.

R. D. Astuti and I. Iftadi, Analisis dan Perancangan Sistem Kerja. Sleman: Deepublish, 2016.

M. P. Groover, Automation, production systems, and computer-integrated manufacturing. Upper Saddle River: Pearson, 2007.

Downloads

Published

2020-07-16

Issue

Section

Research Article

How to Cite

[1]
“Increased line efficiency by improved work methods with the ECRS concept in a washing machine production: a case study”, j. sist. manaj. ind., vol. 4, no. 1, pp. 13–29, Jul. 2020, doi: 10.30656/jsmi.v4i1.2184.

Similar Articles

31-40 of 80

You may also start an advanced similarity search for this article.