Design of Lean Manufacturing Integration to Reduce Waste in NBC 001 Production Flow Using VSM and DMAIC Approach

This research was conducted on NBC 001 products sold by the Nibras brand, engaged in garments. This company sells many products, but the NBC 001 product is the best-selling product because it has sold 12,673 pcs. This study focuses on the waste that occurs in the production process flow. Based on the results of interviews with the warehousing department, it was found that there are 2 (two) types of waste that are the problem, namely defects and the length of production lead time. Then the research was carried out using the lean method, namely a combination of VSM (Value Stream Mapping) and DMAIC (Define-Measure-Analyze-Improve-Control), to get the lean results. This study stated that based on the results of the calculation of DPMO (Defects per Million Opportunities), the defects that occurred were still within the concession provided by the company, namely 5%. And the problem in lead-time production after being calculated and analyzed using VSM (Value Stream Mapping) and DMAIC (Define-Measure-Analyze-Improve-Control) is obtained by combining processes with the same output, namely marker and cutting, adding operators, and adding supermarkets. At work, stations can reduce the value of NVA (Non-Value Added) from 97% to 91% and increase the value of VA (Value Added) from 3% to 9%, then shorten the lead time from 10.4 days to 3 days and speed up the cycle time from 154.5 minutes to 137 minutes