Aplikasi Lean Manufakturing dan Junbiki System Sebagai Upaya Perbaikan Berkelanjutan On Time Delivery di Perusahaan Manufakturing Otomotif

Septony, Esthadi Wahyu (2025) Aplikasi Lean Manufakturing dan Junbiki System Sebagai Upaya Perbaikan Berkelanjutan On Time Delivery di Perusahaan Manufakturing Otomotif. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Persaingan industri manufaktur otomotif menuntut perusahaan menjaga efisiensi operasional dan ketepatan waktu pengiriman (On-Time Delivery/OTD). PT XYZ Karawang masih menghadapi ketidakstabilan OTD akibat pemborosan (waste) pada proses logistic line assembly, khususnya pada distribusi big part menuju line perakitan. Penelitian ini bertujuan menerapkan prinsip Lean Manufacturing melalui Value Stream Mapping (VSM) dan sistem tarik berbasis urutan (Junbiki) untuk meningkatkan kinerja logistik. Penelitian dilakukan melalui observasi langsung (genba), wawancara lintas fungsi, analisis data produksi dan pengiriman, serta diskusi dengan supplier sebagai pilot project implementasi Junbiki. Current Value Stream Map (CVSM) digunakan untuk mengidentifikasi pemborosan pada proses logistic assembly, sedangkan Future Value Stream Map (FVSM) menggambarkan kondisi setelah implementasi Junbiki dan Junbiki Part Order (JPO) yang menghubungkan kebutuhan aktual kendaraan di titik assy-in dengan proses penyiapan dan pengiriman part secara pull by sequence. Hasil penelitian menunjukkan bahwa implementasi Junbiki menyederhanakan aliran logistik melalui eliminasi aktivitas shopping part serta reduksi pemborosan lain seperti inventory, waiting, transportation, dan motion. Selain perbaikan aliran proses, terjadi perubahan pada proses bisnis supplier dan praktik kerja operasional, baik di sisi internal maupun eksternal, yang mendukung pengiriman part berbasis urutan aktual. Secara keseluruhan, penerapan Lean Manufacturing melalui VSM dan sistem Junbiki memperbaiki aliran material dan informasi serta meningkatkan stabilitas On-Time Delivery di PT XYZ. ======================================================================================================================================
The automotive manufacturing industry requires companies to maintain operational efficiency while ensuring reliable On-Time Delivery (OTD). PT XYZ in Karawang continues to experience OTD instability caused by various forms of waste within the logistic assembly process, particularly in the distribution of big parts to the assembly line. This study evaluates the implementation of Lean Manufacturing through Value Stream Mapping (VSM) and a sequence-based pull system (Junbiki) to improve logistics performance and delivery stability. The research was conducted through direct observation (genba), cross-functional interviews, analysis of historical production and delivery data, and coordination with suppliers as part of a Junbiki pilot project. The Current Value Stream Map (CVSM) was used to identify major sources of waste in the logistic assembly process, while the Future Value Stream Map (FVSM) represents the post-implementation condition enabled by the Junbiki Part Order (JPO) system, which synchronizes actual vehicle requirements at the assembly-in point with part preparation and delivery using a pull-by-sequence mechanism. The results show that the implementation of Junbiki simplifies the logistics flow through the elimination of shopping part activities and the reduction of other wastes, including inventory, waiting, transportation, and motion. In addition to process flow improvements, changes also occur in supplier business processes, shifting from schedule-based to sequence-based part delivery, as well as in operational work practices on both the internal and supplier sides. Overall, the application of Lean Manufacturing through VSM and the Junbiki system improves logistics flow quality and contributes positively to OTD stability at PT XYZ.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Just in Time, Lean Manufacturing, On-Time Delivery, Pull System, Value Stream Mapping (VSM)
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Esthadi Wahyu Septony
Date Deposited:	20 Jan 2026 10:01
Last Modified:	20 Jan 2026 10:01
URI:	http://repository.its.ac.id/id/eprint/129862

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