Pre-Delivery Check Process Improvement Using Lean Manufacturing Approach At PT Gemala Kempa Daya

Gunawan, Adhibarata Indra (2022) Pre-Delivery Check Process Improvement Using Lean Manufacturing Approach At PT Gemala Kempa Daya. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Gemala Kempa Daya (GKD) is a subsidiary company of PT Astra Otoparts Tbk that manufactures commercial vehicle chassis and non-frame products for many customers including Company A which covers 71% of the total products volume. Each product is inspected by Pre-Delivery Check (PDC) Division because its preceding process may produce defective products. In 2021, Company A has reported 11 products considered as Not Good even though they have zero defect target. GKD sees this as a very important issue that should be handled appropriately so there is no defective product could be sent to the customer that would disturb the company's business and reputation. The defects detected will lead to an excessive inspection process that causes Non-Value-Added (NVA) activities such as motion and overprocessing in the PDC Division. Thus, Lean Manufacturing approach is utilized to identify and reduce the waste. The inspection process is examined using Process Activity Mapping and Value Stream Mapping. The NVA activities that are considered as critical waste is determined using Genba-Shikumi. Each critical waste’s root cause is identified using the 5 Why’s and Fishbone diagram. Based on the root causes identified, the improvement proposed is implementing a newly designed polybox, enlarging the PDC After PDC area, providing a forklift/stacker AGV, leveling uneven PDC floors, and implementing a training method that improves worker’s inspection skills. Although these suggestions can help the inspection process that is affected by the waste identified, the most effective improvement is by tackling the machinery problem that caused the defects to occur in the first place.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Pre-Delivery Check, Lean Manufacturing, Non-Value-Added, Value Stream Mapping, Process Activity Mapping, Genba-Shikumi, 5 Why’s, and Fishbone Diagram.
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	12 Feb 2026 06:33
Last Modified:	12 Feb 2026 06:33
URI:	http://repository.its.ac.id/id/eprint/132412

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