Journal of Engineering in Industrial Research

h-index: 18     i10-index: 25

Machine Modification and Material Replacement to ‎Reduce Production Cost Using PDCA Method with ‎Fishbone Diagram and Why Why Analysis

Document Type : Original Research Article

Authors

Andriyas Sugiarto
Alvi Octavianto Octavianto
Syafrian Eko Nugroho Nugroho
Yudi Prastyo

Industrial Engineering Study Programme, Faculty of Engineering, Pelita Bangsa University, West Java, Indonesia

https://doi.org/10.48309/jeires.2024.211563
Abstract
In the fierce competition in the Industrial world, meeting customer needs to maintain loyalty and trust is a major concern. In this case, the order received at Job 23xxx was in the form of UNP bending which is a new model and has never been produced. The existing machine does not meet the needs of completing this job; therefore, the initial plan was chosen to use the welded plate. The welded plate is a waste of time and material. Thus, there must be a machine modification for UNP bending. Machine modification is done by adding a stopper (JIG) so that the roll plate machine can turn into a UNP roll machine. Quality and speed of completion time are the main goals so that customers continue to entrust work to our company. PDCA method with fishbone diagram and why analysis is applied in solving this problem. The present study was conducted by comparing the number of process sequences, process time, and material requirements. Welded plate requires 5 process sequences while UNP material only requires 3 process sequences. Completion of work using welded plate requires 4.874 hours while UNP material only requires 0.807 hours for 1 set of products. This means that the process with UNP material only takes 16.65% of the welded plate process. This makes work completion faster. The cost of welded plate material is Rp. 1,335,956 while UNP material is Rp. 950,756, meaning the cost of UNP material is 71% compared to welded plate material. Saving material costs Rp. 385,200 or 29% per 1 set.

Keywords

Machine modification
PDCA
Fishbone diagram
Why analysis
Saving cost

Subjects

OPEN ACCESS

©2024 The author(s). This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this license, visit: http://creativecommons.org/licenses/by/4.0/

 

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Journal of Engineering in Industrial Research
Volume 5, Issue 3
Summer 2024
Pages 136-141

  • Receive Date 28 October 2024
  • Revise Date 01 December 2024
  • Accept Date 15 December 2024

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