Waste Analysis and 5S-Based Improvement Proposals in UPVC Bathroom Door Production
Abstract
The production process of UPVC bathroom doors at Sinar UPVC still faces various wastes that cause low work efficiency. Problems found include unsystematic arrangement of tools and materials, waiting time during the production process, and operator movements that do not provide added value. These conditions have an impact on increasing production time and reducing company productivity. This study aims to identify waste that occurs in the production process, determine the dominant types of waste, and analyze the root causes of waste as a basis for preparing improvement proposals. The research method used is the Lean Manufacturing approach with the application of 5S (Seiri, Seiton, Seiso, Seiketsu, and Shitsuke). Data collection was carried out through direct observation, interviews, documentation, and measurement of process time. Data analysis included waste identification, data adequacy and uniformity tests, Flow Process Charts (FPC), and Fishbone Diagrams to determine the root causes of waste. The results showed that the dominant wastes were motion and waiting. After the implementation of the 5S-based improvement proposals, motion waste decreased by 50.00%, while waiting waste decreased by 53.85%. These improvements also increased production process efficiency by 16.67%. Thus, implementing the 5S method has been proven to reduce waste, improve work area conditions, and increase production efficiency at Sinar UPVC.
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