International Conference on Engineering. Applied Science And Technology LEAD-TIME IMPROVEMENT OF KAM CUTTER PROCESSING USING THE POKA-YOKE METHOD AT A MANUFACTURING COMPANY IN CIKARANG Singgih Juniawan1*. Saiful Hendra2. Hasbullah3. Uti Roysen4. Daruki5. Eka Irawanti6 1,2,3,4,5,6Mercu Buana University. Jl. Meruya Selatan No. Jakarta and 11650. Indonesia ARTICLE INFO Keywords: Lead-Time Kam Cutter Value Stream Mapping Poka-Yoke Manufacture ABSTRACT The KAM Cutter is a cutting blade used to manufacture plastic pellets through underwater pelletizing. A manufacturing company in Cikarang reported that, on average, an order completion rate for KAM Cutter for 2023-2024 was 12,51%, which is highly below expectations. This research will improve production capacity by enhancing lead time on the production floor. Lean Manufacturing tools used in the research involve Value Stream Mapping. Fishbone Diagram. PokaYoke, and Fixture Design. The findings of this research have revealed that by using a new fixture design, the CNC Milling process can reduce the lead time from 15,24 minutes to 2,09 minutes per unit and reduce the Surface Grinding process from 14,88 minutes to 0,87 minutes per unit while maintaining an overall lead time reduction of 84,38%, from 32 minutes to 5 minutes per unit. The above improvements increased production capacity from 6. 507 units/year to 49. units/year, approaching the target of 54. 000 units/year while boosting the company's revenue from IDR 2,47 billion to IDR 18,81 billion per year. Besides, the Non-Value-Added process time was reduced by 68,72%, reflecting significant efficiency improvements in the production process. A 2024 International Conference on Engineering. Applied Science And Technology. All rights reserved IntroductionA Global plastic resin production continues to grow annually, reaching over 368 million metric tons in 2019, driven by the automotive, construction, and packaging sectors . Meanwhile. Indonesia's plastic industry has experienced significant growth in recent years, with production estimated at 7. 04 million tons and projected to rise to 8. 88 million tons by 2029, representing a compound annual growth rate (CAGR) of over 4,5% . This growth drives the increasing demand for cutting tools each year, exemplified by a specific component called the KAM Cutter. The KAM Cutter is a cutting blade that produces plastic pellets via underwater pelletizing, as illustrated in Figure 1. In this process, molten plastic flows through the sprue . and is distributed through the die-face . , where it is cut by the KAM Cutter Blade . to produce granulate . that is cooled by The water-carried granulate is then separated in a hopper. Each KAM Cutter Blade holder can contain various blades, ranging from 6, 12, 18, 20. A Corresponding author. 24, 32, to 40 pieces. The KAM Cutter Blade is a consumable item frequently replaced due to the base material design, which uses S45C for the holder and Nitro for the cutting edge (Figure . After heat treatment, the cutting edge hardness ranges between 52Ae54 HRC, which is softer than the die-face's hardness of 58Ae60 HRC. Additionally, automatic regrinding occurs every hour during production, necessitating blade replacement every 1Ae2 months. Figure 1. Under Water Pelletizing Source: Internal Company, . E-mail address: singgih. djuniawan@gmail. International Conference on Engineering. Applied Science And Technology Cutter, develop a design solution to reduce these lead times and evaluate the resulting improvement in production capacity after implementing the proposed By addressing inefficiencies and optimizing production processes, this study seeks to close the gap between the current production output and market demand, ultimately enhancing the company's ability to meet customer expectations effectively. Methods Figure 2. Various Types of KAM Cutters Source: Internal Company, . At one foreign-invested manufacturing company in Indonesia, the average weekly demand is 1,000 pieces from its European headquarters. However, the company can only supply 125 pieces per week, as shown in Figure 3. The calculated lead time to produce 125 pieces per week over five working days with two shifts per day . hours per shif. minutes per product. Using the same working hours, meeting the market demand of 1. 000 pieces per week would require a lead time of 4. 8 minutes per product, leaving a gap of 33,6 minutes per product that the company must address. 12,31% 12,72% This study employs data collection methods comprising literature reviews and field research. The literature review incorporates theories related to Value Stream Mapping. Fishbone Diagram. PokaYoke. Fixtures, and several relevant journals, while the field research involves interviews, direct observations, and documentation . The data processing methodology in this engineering practice includes the following steps . s illustrated in Figure Calculating Productivity Productivity calculation determines the average machine productivity before and after implementing improvements . The productivity of each machine and the overall average is calculated using Equations 1 and 2. ycEycy ycEyco = . 12,36% 12,69% 12,00% 12,20% 12,40% 12,60% 12,80% Figure 3. Order Fulfillment July 2023-June 2024 Source: Internal Company, . Research conducted by Pytters highlights that various optimization methods for production floor assembly processes in manufacturing industries indicate that Poka-Yoke significantly reduces lead time, decreasing it from 4. 48 minutes to 1,32 minutesAia reduction of 3,26 minutes . Similarly, research by Hernadewita demonstrates that applying the PokaYoke method to the B8A rotor component in an automotive spare parts manufacturing company eliminated dimensional defects in materials entering production, achieving zero defects the following Additionally. Poka-Yoke implementation improved production cycle time to 79,77 seconds per unit . This research aims to identify the root causes of high lead times in the production process of the KAM Explanation: ycEyco : Machine Productivity Index ycEycy : Quantity of products processed . ycyco : Product processing time . ycEyc = Oc ycEyco Oc ycEyco Explanation: ycEyc : Total Machine Productivity Index Oc ycEyco : Sum of Machine Productivity Indices Oc ycEyco : Number of machines used . Developing Value Stream Mapping To facilitate analysis, value stream mapping is created following these steps . Create a Current State Mapping to identify solutions. Identify waste-causing bottlenecks that result in high lead times. Develop a Future State Mapping based on improvements, serving as a foundation for ongoing enhancement. Compare the Current State Mapping and Future State Mapping plots. Singgih Juniawan. Saiful Hendra. Hasbullah. Uti Roysen. Daruki. Eka Irawanti International Conference on Engineering. Applied Science And Technology Data Processing Calculate Productivity Before Value Stream Mapping Current State Mapping Pareto Diagram Waste Identification Poka-Yoke Future State Mapping Desain Fixture presented in Table 1. This data serves as a baseline for comparison with the productivity data after improvements are implemented. Based on the initial data, it is evident that the lowest machine productivity values are below 1, specifically for the CNC Milling and Surface Grinding machines, with respective values of 0,066 pcs/min and 0,067 pcs/min. The overall Machine Productivity Index was calculated to be 1,148 pcs/min. Table 1. Current Productivity Index Material Costs FSM Before Productivity? Figure 4. Flow Process of Research Creating Pareto Diagram A Pareto diagram is created to identify machining processes contributing the most to high lead times . Designing Poka-Yoke The Poka-Yoke stage involves designing fixtures to reduce lead times based on the Pareto diagram findings using CAD/CAM (Computer-Aided Design/Computer Aided Manufacturin. Variables in the fixture design include machine table dimensions, the number of machines used, available operators, and permitted working hours. Calculating Benefit/Cost Ratio The cost-benefit analysis includes calculating material and labour costs alongside the revenue increase resulting from fixture implementation . Results and Discussions Two main processes are required to produce a KAM cutter: machining the cutter body and cutting edge. The body machining involves several stages, including material cutting, body profiling, deburring, welding to attach the body to the cutting edge, finishing, and quality control (QC) inspection before Meanwhile, cutting-edge manufacturing is outsourced to a third party and includes material treatment to achieve a 52Ae54 HRC hardness, followed by cutting using a wire-cut machine. The results of the current state mapping based on these processes are shown in Figure 5. The calculation of the individual and overall Machine Productivity Index at the beginning of the study is Machine/ Process . cs/ minute. 0,066 2,884 1,574 0,067 . cs/ minute. CNC Milling SandBlasting Welding Surface Grinding 1,148 Waste identification was conducted using a Pareto diagram derived from the current state mapping. This study defines waste as the cycle time for each Based on the Pareto diagram in Figure 6, the processes with the most extended cycle times are CNC Milling and Surface Grinding, with 15,24 minutes . ,9%) and 14,88 minutes . ,8%). These two processes account for a cumulative percentage of 94,70%. After identifying improvement areas from the Pareto diagram, a refinement mapping was developed using a fishbone diagram involving experts with over ten years of experience. The results of this activity are shown in Figures 7. Based on the analysis of the fishbone diagrams in Figures 7, the primary causes of high lead times in the CNC Milling and Surface Grinding processes can be addressed by implementing a Poka-Yoke solution involving a more effective fixture design. Factors such as operators' limited understanding of fixture usage, variability in skill levels, improper machine calibration, and inefficient fixture designs for the CNC Milling process contribute to process To resolve these issues, a Poka-Yoke approach can be applied by designing fixtures that only allow materials to be mounted in the correct orientation, thereby minimizing errors. Additionally, the fixture's capacity can be increased from 8 cavities to 20 cavities, significantly reducing lead time. In the Surface Grinding process, issues such as machine vibrations affecting grinding results, fixture instability during operations, and a lack of standardized fixture settings can be resolved with a more stable and modular fixture design. Introducing fixtures capable of absorbing vibrations and equipped with reference points to maintain material positioning Figure 6. Pareto Diagram Figure 5. Current State Mapping Figure 7. Fishbone Diagram International Conference on Engineering. Applied Science And Technology . Figure 8. Fixture Design . Fixture for CNC Milling OP1 . Fixture for CNC Milling OP2 . Fixture for Surface Grinding OP1 . Fixture for Surface Grinding OP2 & OP3 . Fixture for Surface Grinding OP4 . Singgih Juniawan. Saiful Hendra. Hasbullah. Uti Roysen. Daruki. Eka Irawanti International Conference on Engineering. Applied Science And Technology Figure 9. Future State Mapping International Conference on Engineering. Applied Science And Technology Singgih Juniawan. Saiful Hendra. Hasbullah. Uti Roysen. Daruki. Eka Irawanti International Conference on Engineering. Applied Science And Technology enhances the quality of grinding results. Furthermore. Table 3 shows the cost calculation required to increasing fixture capacity from 12 cavities to 40 produce fixtures that increase capacity and reduce cavities allows for significant improvements in process lead time. The total cost for producing five process efficiency. To ensure the sustainability of fixtures amounts to IDR 76. The resulting these improvements, operator training on the usage increase in production capacity significantly of new fixtures and the implementation of improved the company's annual revenue from IDR standardized visual guidelines should be conducted. 000 to IDR 18. This increase This ensures consistent adoption and optimizes the was due to a rise in production from 6. 507 pcs/year benefits of the redesigned fixtures. 518 pcs/year, approaching the company's target The implementation results of the proposed solution of 54. 000 pcs/year. are illustrated in Figure 8. The material ordering Table 3. Fixture Cost model was modified to use materials with pre. levelled surfaces, eliminating the need for planar Name of Part Dimension Material Cost The CNC Milling process was divided into two operations. OP1 and OP2, with the quantity Fixture CNC Mill #380 x 250 x 50 of KAM Cutters on the fixture increasing from 2 OP 1 #460 x 250 x 50 Fixture CNC Mill SNCM pieces per cycle to 20 pieces per cycle. This OP 2 #760 x 115 x 50 adjustment significantly reduced the lead time in the Fixture Surface (Flame Hardened previous process (Figures 8a and 8. In this new Grinding OP 1 #760 x 115 x 50 Surface process, the cycle time decreased from 15,24 minutes Fixture HRC) Grinding OP 2 & 3 per piece to 2,09 minutes per piece. Furthermore, by Fixture Surface #760 x 115 x 75 increasing the fixture capacity on the Surface Grinding OP 4 Total Cost Grinding machine from 12 pieces per cycle to 40 pieces per cycle across four operational steps, the Based on the significant achievements of this study, cycle time was reduced from 14,88 minutes per piece the company has implemented a new policy to 0,87 minutes per piece (Figures 8c, 8d, and 8. involving the reorganization of the CNC Milling The future state mapping process was conducted to process into two operations. OP1 and OP2, while assess the extent of improvements made objectively maintaining four operations for Surface Grinding and to serve as a reference for future enhancements (OP1. OP2. OP3, and OP. However, the number of (Figure . As shown in Figure 9. Non-Value-Added cavities per process for surface grinding has been (NVA) processes decreased significantly, from 7,901 increased to 40 pcs per process, which aligns with the minutes to 2. 471 minutesAia reduction of 5. 430 new fixture design. Additionally, the company has minutes or 68,71%. Similarly. Value-Added (VA) provided worker training for operators on using the processes also declined, from 32 minutes to 5 improved fixture and will conduct evaluations every minutes, representing a reduction of 27 minutes or four months to ensure consistency in the achieved If production operators consistently perform their tasks effectively, the company plans to extend The calculation of the Machine Productivity Index, similar improvements to other products to achieve both individual (P. and overall (P. , after the optimal productivity. Furthermore, the company will improvements can be seen in Table 2. The table continuously enhance market penetration to increase indicates that the lowest individual Machine sales and competitiveness. Productivity Index (P. was for CNC Milling, which still showed improvement from 0,066 to 0,487. The Compared to the research by Pytters, which reduced overall Machine Productivity Index (P. improved lead time from 4. 48 minutes to 1. 32 minutes . from 1,148 to 1,694. This indicates that the process reduction of 70. 54%), the lead time reduction improvements implemented were practical and achieved in this study is more substantial at 84. from an initial lead time of 32 minutes to 5 resulted in better performance. Unlike the study by Hernadewita, which Table 2. Future Productivity Index successfully reduced defect rates to zero but increased the production cycle time by 79. Machine/ Process seconds, this study maintained a zero defect rate from . cs/ minute. (/ minute. the beginning of the production process. CNC Milling 0,066 simultaneously reduced the production cycle time to SandBlasting 2,884 1,148 5 minutesAia significant improvement of 84. Welding 1,574 Surface Grinding 0,067 International Conference on Engineering. Applied Science And Technology Conclusions This report is compelling enough to point out and resolve the main difficulty resulting in long lead times in the production of KAM Cutter at a manufacturer located in Cikarang. By adopting some of the techniques of Lean Manufacturing, including Value Stream Mapping. Fishbone Diagram, and Poka-Yoke, the company can improve its production process and create a much better fixture design. The improvement will result in a significant increase in production efficiency, the ability to cope with demand, and reduced non-value added. Additionally, the company conducts regular activities for constant improvement: operators' training and regular evaluation to support improvements and planning to apply similar methods to other products. Research has shown that appropriate methods in production management may have a relatively positive impact Author Contributions For research articles with several authors, a short paragraph specifying their individual contributions must be provided. The following statements should be used AuConceptualization. Singgih Juniawan and Saiful Hendra. Saiful Hendra. Singgih Juniawan. Hasbullah. Daruki and Uti Roysen. formal analysis. Saiful Hendra. Singgih Juniawan. Singgih Juniawan. data curation. Eka Irawanti. writingAioriginal draft preparation. Singgih Juniawan. writingAireview and editing. Daruki. Eka Irawanti. Sauful Hendra. project administration. Eka Irawanti. funding acquisition. Uti Roysen. All authors have read and agreed to the published version of the Ay Please turn to the CRediT taxonomy for the term explanation. Authorship must be limited to those who have contributed substantially to the work Conflicts of Interest Declare conflicts of interest or state AuThe authors declare no conflict of interest. Ay Authors must identify and declare any personal circumstances or interest that may be perceived as inappropriately influencing the representation or interpretation of reported research results. Any role of the funders in the design of the study. in the collection, analyses or interpretation of data. in the writing of the or in the decision to publish the results must be declared in this section. If there is no role, please state AuThe funders had no role in the design of the study. in the collection, analyses, or interpretation of data. in the writing of the manuscript. or in the decision to publish the resultsAy. References