ANALYSIS THE APPLICATION OF LEAN MANUFACTURING WITH SYSTEMATIC HUMAN ERROR REDUCTION AND PREDICTION TO REDUCE DEFECT PRODUCTION

Abstract

Manufacturing companies engaged in wood processing produce products in the turning process. The problem faced by the company is a waste where defects often occur in each production process. The cause of the disability arises in workers with human error. This research aims to minimize the waste in activities that do not provide added value and find the factors that cause a human error in the turning production process. For this reason, the method is used to Value Streaming Mapping illustrate the flow of products, the entry of raw materials to finished products. The research was distributing questionnaires to the production department and then processed with a waste assessment model, waste relationship matrix and waste assessment questionnaire so that the three highest wastes were obtained, namely waste defects (27,979%), waste overproduction (15,471%) and waste inventory (12,363%). Weighting waste with value stream analysis tools by selecting the two highest tools, namely process activity mapping and quality filler mapping. The causes of activities and accuracy are caused by human errors in the production process using the Systematic Human Error Reduction and Prediction method. Five activities are obtained in a critical state. The results of field implementation showed improvement with a decrease in time from 2384.2 minutes to 2247.4 minutes the value of Process cycle efficiency with the improvement of 4.9185%.