Design of Equipment Rack with TRIZ Method to Reduce Searching Time in Change Over Activity (Case Study : PT. Jans2en Indonesia)

Abstract

Janssen is a manufacturing plant that works in furniture assembly. Component shortages often occurs, it will cause the increase of work in process (WIP) in assembly section. In previous studies, we analyze the root causes with FMEA and then it is resulted that router section is the constraint of the system. There are many non value added activities such as searching and transportation caused by a messy condition of work places and the devices that aren’t put in the right place. The impact is that the time allocated for every change over is higher than before. There are many components that are worked by the router section, so improvements are needed to minimize changes in over time. 5S method and the use of a new design of rack by TRIZ method are suggested for fixing the conditions of work environment. It is expected to eliminate non value added activities and changes in over time. Result shows that we can reduce non value activities in change over of regular components up to 41% and the elimination of this time is 41,6%. The non value activities in changeover of new items is 36,6% and this elimination of time is 53,3%. Key word : change over, kaizen, design, TRIZ method