Operator Performance Analysis and Enhancement Proposals for the Final Regulation Assembly Upright Piano Group

Abstract

PT Yamaha Indonesia is a manufacturing company that produces pianos and has a program in place to periodically increase its productivity. The production process which is mostly done manually, is a challenge, especially for operators because they play an important role in achieving productivity targets. In the Final Regulation UP group, several problems occur, making it impossible to achieve the productivity target. The problems in this group are the excessive number of operators, below-target production outcomes, and a high number of reworked products. Therefore, it is necessary to find out the effectiveness of this working group using the Overall Labor Effectiveness (OLE) method. Then it will continue with an analysis of the results using the Root Cause Analysis (RCA) tools, which will then be given kaizen or suggestions to solve existing problems. Following that, the findings will be analyzed using Root Cause Analysis (RCA) tools, and kaizen, or recommendations for solving current issues will be provided. The Overall Labor Effectiveness (OLE) value of the Final Regulation UP working group during 34 days of observation was 79% with a value availability ratio of 96%, performance ratio of 97%, and quality ratio of 85%, the OLE score is below the international standard due to the lower quality ratio. After kaizen was implemented, the OLE score increased to 89% with the value obtained from the variables 98% for the availability ratio, 98% for the performance ratio, and 92% for the quality ratio. All of the three variables are increased, making the OLE score higher than before.