Waste Analysis and Lean Manufacturing Development in Heavy Equipment Component Industry

Competition in the heavy equipment industry in Indonesia is getting tighter and tighter. Increased demand for heavy equipment needs in the coal industry in Indonesia and coupled with support from the Indonesian Ministry of Industry in the down streaming of coal, the heavy equipment industry can also increase production if it refers to these demands in maintaining or increasing the market share of these products.Based on the results of the analysis in this study that the identification of waste in the head rod product machining process explains the low level of production achievement results in a significant difference between the achievements of production with the production target on the head rod for heavy equipment components.The current state mapping shows that there is a high processing time for the Beld Weld and Drill + Tap processes with direct measurement of processing time. Meanwhile, the number of rejects produced was with a sigma value of 2.79 in that period. The types of waste obtained include processing, motion, transportation, inventory, and defects. The identification of causes is carried out with the 5W1H approach and why-why analysis in the Focus Group Discussion of parties related to these causes which includehuman, machine, material, and method factors.These include processing, motion, and defects in the beld weld and drill + tap processes. The identification of causes is done with the 5W1H approach and why-why analysis in the Focus Group Discussion of parties related to these causes which include human, machine, material, and method factors.