DOI: https://doi.org/10.14710/jati.21.2.%25p

LEAN-BASED OPTIMIZATION OF SMALL SCALE CONCRETE BLOCK PRODUCTION

*Kumara Pinasthika Dharaka orcid scopus  -  Universitas Bina Nusantara, Indonesia
Ega Rizkiyah orcid scopus  -  Institut Teknologi Sepuluh Nopember, Indonesia
Ardian Lintang Samudro  -  Universitas Bina Nusantara, Indonesia

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Abstract

This research addresses key inefficiencies in concrete block production within small-to-medium-sized manufacturers in Indonesia, where challenges such as long processing times, excessive motion, overstocking, and product defects significantly hinder productivity. The study aims to identify the root causes of these wastes and develop an integrated lean-based improvement strategy to enhance operational efficiency and product quality. A current state value stream mapping (VSM) analysis was conducted to visualize the production flow and identify non-value-added activities and bottlenecks. A Fishbone Diagram was then used to systematically determine the underlying causes of inefficiencies. To address ergonomic issues, the Rapid Upper Limb Assessment (RULA) method was applied to compare operator posture before and after tool modifications. Key improvements include standardized material measurements, optimized layout design to reduce transportation waste, a lever-press molding machine for improved ergonomics, and enhanced cement storage conditions. These interventions shortened the drying period from two months to 28–32 days and doubled the daily output from 300 to 600 blocks. Ergonomic evaluations showed a RULA score reduction from 5 to 3, indicating better posture and reduced fatigue. Overall, this study provides a practical framework for applying lean principles in small-scale construction material production.

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Keywords: lean manufacturing; process optimization; ergonomics evaluation; small-scale manufacturing

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Section: Research Articles
Language : EN
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