Waste Analysis to Increase Productivity of Metal Press Line in Motorcycle Discbrake Industry using Work Study and Lean Manufacturing Methods

The motorcycle component industry as part of the national strategic industry has made a significant contribution to the country's economic growth. The problems still facing are the availability of most of raw material still imported, mastery of the latest technology, and still low fulfillment of production targets. Based on previous studies, among the main reasons are the effective use of machine time is still low and low work productivity which is the cause of incorrect production system selection and poor machine layout, causing a lot of waste which leads to high production process time. This paper aims to help remove the waste that appears in the metal pressing line by using analysis of work studies, production systems, machine layout, line balancing, and application of lean manufacturing principles. As a result of the improvements made, the valueless activity waste can be reduced by 15 activities which affects the increase in machine efficiency by 21.5%, machine utility by 18.2%, and work productivity by 27%. As a result, production targets increased from 85.2% to 94.7% and other benefits from production cost savings.