The Use of Flow Rack as an Effort to Implement Kaizen in an Effort to Increase the Production of Stepwagon Car Seats at PT YSC Japan

Abstract

This study aims to: (1) analyze the performance data of workers at PT. YSC Japan before the implementation of an innovation involving the addition of a Flow Rack; (2) examine the process of adding the Flow Rack and its impact on worker performance at PT. YSC Japan; and (3) evaluate how the Flow Rack innovation enhances worker productivity at PT. YSC Japan. The study employs the Kaizen concept using the 8-Step Improvement method, with a fishbone diagram utilized for cause-and-effect analysis. Data were collected through observation and documentation, using instruments such as a logbook, observation sheet, and smartphone. Descriptive quantitative analysis was conducted to compare production speeds before and after process improvements. The findings reveal that: (1) PT. YSC Japan required efficiency enhancements, as production on the Line Front Cushion Stepwagon experienced a loss time of 90 seconds per 22 pieces, resulting in a production time of 38.7 seconds per piece; (2) the application of the Kaizen concept, using the 8-Step Improvement method, successfully improved productivity through the addition of a Flow Rack as a storage innovation; and (3) after implementing this change, PT. YSC Japan achieved a 10.3% efficiency improvement, reducing production time to 34.7 seconds per piece.