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Abstract
Recently Indonesian textile and garment manufacturer has experienced a problem with shop floor production. The complexities in the manufacturing process led to many problems such as the inefficiency, and thus prevented the company from achieving its target. In fact, even though the company has established the efficiency target of 80%, the production floor cannot realize it. Thus, this research aims to increase the line efficiency to reach the company’s target. At the beginning of the analysis, the efficiency of assembly line was only 51,68%. Since, this value did not meet the company’s target and was not satisfying; the concept of ECRS was applied. The purpose of this research is to simplify the method to provide better effect and process flow. Before applying the method, the fishbone diagrams were used. The factors of man, method, machine and measurement were used to describe the root cause of the losses. Thus, after applying the concept of ECRS, the efficiency level increased to 81,54%, which had met the company’s target. The assembly line will run better and smoother with the smaller possibility of bottleneck if all of the workstations have a relatively balanced workload.
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References
Baroto, T. (2002). Pengantar Teknik Industri. Universitas Muhammadiyah Malang.
Bârsan, R. M., & Codrea, F.-M. (2019). Lean university: applying the ECRS method to improve an administrative process. MATEC Web of Conferences, 290, 07003. https://doi.org/10.1051/matecconf/201929007003
Bukchin, Y., & Raviv, T. (2018). Constraint programming for solving various assembly line balancing problems. Omega, 78, 57–68.
Hui, C., & Ng, S. (1999). A study of the effect of time variations for assembly line balancing in the clothing industry. International Journal of Clothing Science and Technology, 11(4), 181–188.
Kelendar, H., & Mohammed, A. M. (2020). Lean And The Ecrs Principle: Developing A Framework To Minimise Waste In Healthcare Sectors. International Journal of Public Health and Clinical Sciences, September. https://doi.org/10.32827/ijphcs.7.3.98
Limcharoen, A., Wannarat, J., & Panich, V. (2007). The Application of Line Balancing Technique and Simulation Program to Increase Productivity in Hard Disk Drive Components. World Academy of Science. Engineering and Technology International Journal of Computer and Information Engineerin, 11(9), 1074–1078.
Luo, Y., Huang, S., & Cao, S. (2007). Application of improved fishbone diagram in the operation management. Industrial Engineering Journal, 25(2).
Macías-Jiménez, M. A., Romero-Conrado, A. R., Acosta-Fontalvo, L. C., & Coronado-Hernández, R. (2019). Application of Work Study to Process Improvement: Fruit Nectar Case. In In: Saeed K., Chaki R., Janev V. (eds) Computer Information Systems and Industrial Management. CISIM 2019 (Vol. 11703). Springer.
Nasution, A. H. (1999). Perancangan dan Pengendalian Produksi. Jurusan Teknik Industri ITS.
Nisa, A. K., Hisjam, M., & Helmi, S. A. (2021). Improvement of Work Method with Eliminate, Combine, Re-arrange, and Simplify (ECRS) Concept in a Manufacturing Company: A Case Study. IOP Conference Series: Materials Science and Engineering, 1096(1), 012016. https://doi.org/10.1088/1757-899x/1096/1/012016
Nisphaphat, N., & Ratanakuakangwan, S. (2016). Waste Reduction in Surface Treatment Process by Lean Six Sigma Approach. IRO Transactions On Science And Technology, 1(1), 35.
Nourmohammadi, A., & Eskandari, H. (2017). Assembly line design considering line balancing and part feedin. Assembly Automation, 37(1), 135–143.
Ongkunaruk, P., & Wongsatit, W. (2014). An ECRS-based line balancing concept: a case study of a frozen chicken producer. Business Process Manageent Journal, 20(5), 678–692.
Suhardi, B., Anisa, N., & Laksono, P. W. (2019). Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent Engineering, 6(1), 1–13. https://doi.org/10.1080/23311916.2019.1567019
Xing, W. (2004). QC Team Based Materials. Beijing: China Society Press.
References
Baroto, T. (2002). Pengantar Teknik Industri. Universitas Muhammadiyah Malang.
Bârsan, R. M., & Codrea, F.-M. (2019). Lean university: applying the ECRS method to improve an administrative process. MATEC Web of Conferences, 290, 07003. https://doi.org/10.1051/matecconf/201929007003
Bukchin, Y., & Raviv, T. (2018). Constraint programming for solving various assembly line balancing problems. Omega, 78, 57–68.
Hui, C., & Ng, S. (1999). A study of the effect of time variations for assembly line balancing in the clothing industry. International Journal of Clothing Science and Technology, 11(4), 181–188.
Kelendar, H., & Mohammed, A. M. (2020). Lean And The Ecrs Principle: Developing A Framework To Minimise Waste In Healthcare Sectors. International Journal of Public Health and Clinical Sciences, September. https://doi.org/10.32827/ijphcs.7.3.98
Limcharoen, A., Wannarat, J., & Panich, V. (2007). The Application of Line Balancing Technique and Simulation Program to Increase Productivity in Hard Disk Drive Components. World Academy of Science. Engineering and Technology International Journal of Computer and Information Engineerin, 11(9), 1074–1078.
Luo, Y., Huang, S., & Cao, S. (2007). Application of improved fishbone diagram in the operation management. Industrial Engineering Journal, 25(2).
Macías-Jiménez, M. A., Romero-Conrado, A. R., Acosta-Fontalvo, L. C., & Coronado-Hernández, R. (2019). Application of Work Study to Process Improvement: Fruit Nectar Case. In In: Saeed K., Chaki R., Janev V. (eds) Computer Information Systems and Industrial Management. CISIM 2019 (Vol. 11703). Springer.
Nasution, A. H. (1999). Perancangan dan Pengendalian Produksi. Jurusan Teknik Industri ITS.
Nisa, A. K., Hisjam, M., & Helmi, S. A. (2021). Improvement of Work Method with Eliminate, Combine, Re-arrange, and Simplify (ECRS) Concept in a Manufacturing Company: A Case Study. IOP Conference Series: Materials Science and Engineering, 1096(1), 012016. https://doi.org/10.1088/1757-899x/1096/1/012016
Nisphaphat, N., & Ratanakuakangwan, S. (2016). Waste Reduction in Surface Treatment Process by Lean Six Sigma Approach. IRO Transactions On Science And Technology, 1(1), 35.
Nourmohammadi, A., & Eskandari, H. (2017). Assembly line design considering line balancing and part feedin. Assembly Automation, 37(1), 135–143.
Ongkunaruk, P., & Wongsatit, W. (2014). An ECRS-based line balancing concept: a case study of a frozen chicken producer. Business Process Manageent Journal, 20(5), 678–692.
Suhardi, B., Anisa, N., & Laksono, P. W. (2019). Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent Engineering, 6(1), 1–13. https://doi.org/10.1080/23311916.2019.1567019
Xing, W. (2004). QC Team Based Materials. Beijing: China Society Press.