LEAN MANUFACTURING APPROACH USING COST INTEGRATED VALUE STREAM MAPPING TO REDUCE WASTE IN FAKE EYELASHES PRODUCTION FLOOR

Abstract

Fake eyelashes are made in Indonesia by a variety of industries. There are issues
within the company that have an impact on the output. Waste issues in the
manufacture of fake eyelashes are the cause of inconsistent production output,
such as flaws in the goods, waiting times, and improper processing. A lean
manufacturing approach is required to find a solution to the issues that PT. X
is experiencing as a result of the data model. The Value Stream Mapping (VSM)
method, the Activity Based Costing (ABC) method integration, the Value
Stream Analysis Tools (VALSAT) method calculation, the Root Cause
Analysis (RCA) method, and then gives recommendations for improvement.
The use of continuous flow, task combinations, and the delivery of raw
materials once each week are all suggested improvements. When current cost
integrated value stream mapping is compared to future cost integrated value
stream mapping, the production lead time drops from 0.5 days to 0.36 days,
the total value-added cost drops from 2.049 to 1.561, the total non-value-added
cost drops from 12.754 to 11.243, and the travel distance drops from 99 meters
to 79 meters.