Efficiency Analysis of Underframe Component Installation Process in the KCI Retrofit Electric Multiple Unit (EMU) Project at PT xxx using a Lean Manufacturing Approach
Analisis Efisiensi Proses Pemasangan Komponen Underframe pada Proyek KRL KCI Retrofit di PT xxx dengan pendekatan Lean Manufacturing
DOI:
https://doi.org/10.21070/44edbd30Keywords:
Underframe, Lean Manufacturing, Waste Of Waiting, Waste Of Defect, Workflow FragmentationAbstract
General Background PT xxx is an integrated railway manufacturing enterprise facing major challenges in retrofitting legacy rolling stock from the 1990s due to dimensional tolerances and structural complexities. Specific Background The KRL KCI Retrofit Project exhibits severe inefficiencies and high delays during underframe component installation. Knowledge Gap Existing processes lack structured priority signals and systematic waste identification under complex legacy constraints. Aims This study aims to identify and classify core wastes using Lean Manufacturing methods and formulate future-state improvements. Results Findings indicate that Waste of Waiting is the most dominant constraint causing workflow fragmentation, compounded by dimensional mismatches causing Waste of Defect and rework. Novelty The integration of qualitative Hoshin Kanri for strategic milestone setting, Poka-Yoke quality gates, and Kaizen lesson-learned systems addresses legacy retrofit bottlenecks. Implications These measures optimize assembly flow and enhance productivity in rail vehicle manufacturing.
Key Findings Highlights
1. Waste of waiting stands out as the primary constraint causing severe workflow fragmentation during underframe assembly.
2. Dimensional discrepancies in fabricated brackets generate high defect rates and frequent rework cycles.
3. Implementing structured milestone planning and quality gates effectively resolves operational bottlenecks.
Keywords Underframe, Lean Manufacturing, Waste Of Waiting, Waste Of Defect, Workflow Fragmentation
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