TABLE OF CONTENT
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables vi
List of Figures vii
List Abbreviations viii
CHAPTER 1: INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 3
1.3 Objectives
4 1.4
Scope of Study 4
1.5 Report Structure
5
CHAPTER 2: LITERATURE REVIEW 7
2.1 The Definition of Lean in Manufacture Industry
7 2.1.1 Lean Principle
9 2.1.1.1 Specify Value
10 2.1.1.2 Value Stream
10 2.1.1.3 Create Flow
11 2.1.1.4 Pull
11 2.1.1.5 Perfection
11 2.1.2 Lean Tools and Technique
12 2.1.3 Value Stream Mapping
13 2.3.3.1 Values Stream Mapping Icons
15 2.1.3.2 Value Stream Mapping Phase
16 2.1.3.3 Current State Map
17
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2.1.3.4 Future State Map 18
2.1.3.5 Benefits of Value Stream Mapping 19
2.1.3.6 Limitation of Value Stream Mapping 20
2.1.3.7 Various Method used in Value Stream Mapping 20
2.2 Simulation
22 2.2.1 Simulation of Manufacturing System
23 2.2.2 Development of Manufacturing Simulation
23 2.2.3 Application Areas of Manufacturing Simulation
23 2.2.4 Simulation Model Study
26 2.2.5 System and System Environment
26 2.2.6 Component of the System
27 2.2.7 Discrete and Continuous System
27 2.2.8 Model of a System
28 2.2.9 Types of Models
28 2.2.10 Discrete-event System Simulation
28 2.3
Value Stream Mapping and Simulation 29
2.4 Summary
31
CHAPTER 3: METHODOLOGY 32
3.1 Planning of Study
32 3.1.1 Gantt Chart
35 3.2
Collection Data 37
3.2.1 Primary Source 37
3.2.1.1 The Process flow of the Production Line 38
3.2.1.2 Time Study 38
3.2.2 Secondary Source 38
3.3 Steps in Simulation Study
39 3.3.1 Problem Formulation
40 3.3.2 Setting of Objective and Overall Project Plan
40 3.3.3 Model Conceptualization
40 3.3.4 Data Collection
41 3.3.5 Model Translation
41 3.3.6 Model Verification
42
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3.3.7 Model Validation 43
3.3.8 Experimental Design 43
3.3.9 Runs and Analysis 43
3.3.10 Testing 44
3.3.11 Documentation and Reporting 44
3.4 Summary
44
CHAPTER 4: RESULT AND DISCUSSION 45
4.1 Production Line for Safety Pin
45 4.2
Data Collection 48
4.2.1 Demand, Cycle Time and Working Hours 48
4.2.2 Capacity 49
4.3 Developing Current State Value Stream Mapping
50 4.3.1 Analysis of Current State Value Stream Mapping
53 4.4
Conceptual Modelling 54
4.4.1 Modelling Objectives 55
4.4.2 Experimental Factors and Responses 56
4.4.3 Model Scope 56
4.4.4 Model Simplification 57
4.5 Development of Simulation Model
57 4.5.1 Element of the Model
58 4.6
Base Model for Current State 59
4.6.1 Model Assuption 62
4.6.2 Running Model 62
4.7 Verification and Validation
63 4.8
Analysis of Current Simulation Model 64
4.9 Improvement Simulation Model
65 4.9.1 Scenario 1
66 4.9.2 Scenario 2
67 4.9.3 Scenario 3
68 4.9.4 Scenario 4
70 4.10
Comparison of All Alternatives 71
4.11 Final Improvement
72
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4.12 Summary
72
CHAPTER 5: CONCLUSION FUTURE WORK 73
