Abstract:

Lean manufacturing tools have been applied in a construction company, named AME Engineering Industries Sdn. Bhd. at Taman Teknologi Johor, Skudai. This project aims to identify the problems of the operations by using Value Stream Mapping and develop alternatives with WITNESS simulation software. Based on the current state value stream map, the Value Added (VA) ratio of the production is 0.4297. The analysis shows that the most critical problem is the high queue time between QC Inspection and Painting Primer Coat process due to unbalanced process. Single Kanban, CONWIP and Hybrid Kanban/CONWIP have been suggested and evaluated using WITNESS. The simulation results indicates that the Hybrid Kanban/CONWIP is the most suitable alternative. Based on the future state value stream map, the VA ratio has gained 11.63% to 0.480, indicating that Hybrid Kanban/CONWIP could effectively reduce the high queue time between QC inspection and Painting Primer Coat processes.