TRANSFORMER PRODUCTION IMPROVEMENT BY LEAN AND MTM-2 TECHNIQUE

Abstract

The situation of the covid-19 epidemic is a driving force of the global market’s demand increase of electronic devices and parts. Entire electronic component manufacturers, especially the transformer manufacturing industry, which is a device that supplies power to many electronic devices, encounters problems in producing products that are unable to keep up with the quickly increasing demand. This research aims to increase the productivity of small transformers by lean approach. The paper depicts processes relevant to improving production processes, reducing waste, and finding unnecessary processes. The method begins with two actions. First, study the current situation in transformer manufacturing of a case study. Second, study the customer order to delivery process using the Value Stream Mapping (VSM) and analyze entire processes of transformer manufacturing to identify standard time by unit work. The main technique is for measuring working time by timing the forward motion with the time measurement method version 2 (MTM-2). The Cause and Effect diagram was displayed with improving guidelines on two operations. First the concept of lean manufacturing was used in principal role, second the ECRS technique (Eliminate, Combine, Rearrange and Simplify) was applied to reduce "waste" as well as to optimize and reduce the manufacturing process of the transformer. The results lead to an increase in the final product per hour from 45 pieces per hour to 75 pieces per hour which increases up to 30% per hour. In addition, the productivity improvements increased the productivity of 3.46 workers per hour to 6.82 per hour (increase of 97.11%) and production time was reduced from 1,109 seconds to 229 seconds (73.04% of productivity).