Improvement of Production Performance Using WAM & VALSAT Method in Liquid Soap Line

Abstract

Overall Equipment Effectiveness performance in liquid soap line was 47.7% in 2020 where the OEE target in liquid soap line was 60%. This research will focus on eliminating waste to improve liquid soap line's OEE performance by analyzing waste using lean manufacturing tools. The methodology that used to solve this problem is by using WAM and VALSAT method combined with Six Sigma with DMAIC concept. In define phase, Value Stream Mapping was carried out to analyze the current condition in liquid soap line. Hereinafter, in measure and analyze phase, WAM and VALSAT was carried out to obtain the identification of waste and analyze the waste which causes low OEE in liquid soap line. This happens because of frequency of change over. Frequently changeover can lead low OEE due to production without output. The queuing of materials at the freight elevator is also the cause of low productivity. In the improvement phase, the author implement remapping product and production process redesign. After implementation, OEE increased from 47.7% to 55.5% and productivity increased from 96.7% to 97.9%. In control phase, the author suggests new total productive maintenance (TPM) as the control phase. EEM pillar was added to TPM to maintain performance monitoring process in liquid soap line.