Assessing Wastes in Rubber Production Using Lean Manufacturing: A Case Study

This paper aims to assess wastes in the rubber production process using lean manufacturing approach. Waste Relationship Matrix (WRM) and Waste Assessment Questionnaire (WAQ) are used to identify the wastes. Value Stream Analysis Tools (VALSAT) are then determined to analyze the wastes. Next, Fishbone Diagram is used to determine the root causes of wastes. Finally, Failure Mode and Effect Analysis (FMEA) method is applied to identify the failure modes of wastes and develop the action plans. The results show that defects, motion, and transportation indicated as the three major type of wastes in the rubber production process. Process Activity Mapping (PAM) is selected as the analysis tools. It is obtained that the necessary but non value added activities are the most frequent activities in the rubber production. The highest failure mode of the rubber production process is the klahar of mill is broken, followed by the motor of grinding machine is damaged and the processing material is dirty. The failure modes are mostly caused by the production equipment and the quality of raw material. Therefore, it is needed to improve the maintenance program and the quality control of raw material. It is hoped the rubber company can improve the production process to be more efficient and effective.