Optimizing Material Productivity in Fiberglass Boat Manufacturing Using Value Stream Mapping

A.W. Ahmad, M. Darsin, W. Sakinah, H.I.D. Puspita

Abstract


The shipbuilding industry must increase productivity to meet the demands of an increasingly competitive market. However, during ship production, various types of waste are still generated, resulting in low material utilization efficiency and increased production time. This study aims to optimize ship material productivity by applying lean manufacturing concepts through value stream mapping (VSM). The literature review in this study focuses on lean manufacturing concepts, the identification of seven types of waste, and analytical approaches such as the waste relationship matrix (WRM) and value stream mapping. The research used a quantitative descriptive design, collecting data through direct observation, interviews, and questionnaires distributed to respondents involved in the production process. The study found that the dominant waste categories are waiting, defects, overprocessing, transportation, and inventory. Through current-state and future-state map analyses, improvement proposals were developed, including implementing reuse molding, workflow arrangement, pre-kitting, layout optimization, and coordination between processes. The implementation of these improvements reduced non-value-added activities(or increased efficiency) by 26.7%shortened production lead time by 5.5%. Thus, value stream mapping has proven effective in improving material productivity in the fiberglass boat manufacturing process.

Keywords


Productivity; Lean manufacturing; Value stream mapping; Process efficiency

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References


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DOI: https://doi.org/10.29303/dtm.v16i2.1302

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