Aplikasi Konsep Kaizen Dengan Pendekatan Perbaikan Proses Untuk Menurunkan Produk Cacat pada Proses Perakitan Baterai

Abstract

Currently minimizing the level of product defects is the target of all manufacturing production lines, including automotive battery production processes. The purpose of this study was to reduce the level of dominant defects especially in the battery assembly process with Kaizen approach through 8 PDCA cycles. The implementation of Kaizen involves all parties in the company, both management and employees to obtain optimal results. The 8 cycles conducted in Kaizen implementation include Theme Determination, Target Determination, Current Situation Analysis and Cause Analysis, Cause Problem Analysis, Improvement Plan, Improvement Implementation, Result Evaluation, and Standardization. From the implementation results before Kaizen is used the defect rate in the automotive battery production process is 0.548% with the largest type of defect being the plate scrap in the battery assembly process. The implementation of Kaizen through 8 cycles of PDCA conducted for 6 months successfully reduced the defect rate by 20% to be able to meet the company's scrap target and means with continuous improvement it is able to reduce scrap plate in line with the target and from this result many benefits obtained by the company directly and indirectly.indirectly.