Arya Dany Ardhiansah (1), Joumil Aidil Saifuddin Z.S. (2)
General Background The railway manufacturing industry faces increasing demands for high operational efficiency and rapid production cycles to remain competitive. Specific Background PT XYZ, a strategic rail vehicle manufacturer in Indonesia, currently experiences significant bottlenecks in its Bogie production line, characterized by high Work-in-Process (WIP) accumulation and excessive lead times. Knowledge Gap While lean methodologies are well-documented, there is limited research providing an integrated framework that combines Value Stream Mapping (VSM) with real-time digital E-Kanban systems for complex bogie manufacturing environments. Aims This study seeks to identify and reduce critical waste—specifically overproduction, waiting, excess inventory, and overprocessing—within the Bogie production line. Results Through Current State VSM and Process Activity Mapping (PAM) under the Value Stream Analysis Tools (VALSAT) framework, the research reveals substantial process inefficiencies. The implementation of a SQL-backed E-Kanban system and synchronized digital dashboards resulted in a lead time reduction from 3,480 minutes to 2,985 minutes, achieving a total saving of 495 minutes. Furthermore, Process Cycle Efficiency (PCE) improved from 75.8% to 88.4%. Novelty This research offers a concrete, scalable framework for shop-floor digital transformation, merging traditional lean principles with real-time digital pull-based signaling. Implications These findings provide PT XYZ and similar heavy-manufacturing sectors with a validated roadmap for operational optimization, demonstrating that digital-lean integration is essential for modernizing manufacturing processes and achieving superior industrial productivity.
Highlights
Keywords: Bogie, E-Kanban, Lean Manufacturing, Process Cycle Efficiency, Value Stream Mapping
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