Waste Reduction in Manufacturing Companies for Continuous Quality Improvement Using Waste Assessment Model (WAM) And Deming Cycle Method (PDCA)

Abstract

This paper explains what wastes occur in the work environment, namely overproduction, waiting, transportation, overprocessing, motion and defect. The goal of this study is how to identify critical waste and identify the source of waste that occurs in the work environment and then reduce the waste by WAM and PDCA methods. The method used to identify waste is the waste assessment model (WAM). The waste assessment model consists of 2 stages, namely waste relationship matrix (WRM) and waste assessment questionnaire (WAQ). From the results of waste assessment models will be obtained the most dominant waste that occurs in the work environment so that it can be prioritized to be completed compared to other arising waste. Then the most dominant waste is improved by the Deming cycle (PDCA) method consisting of 8 steps. The results of this study obtained critical waste from 7 waste, namely waste defects and the source of the cause of waste defects is the frequency of damage that occurs in the dewatering area. The company lost the opportunity to process raw materials as much as 46,395 kg within 6 months and within the quarter waste has been eliminated to maximize the production process.