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Section Engineering

Lean Supply Chain Reduces Waste in Medical Garment Manufacturing


Penerapan Lean Supply Chain untuk Mengurangi Pemborosan pada Industri Manufaktur Pakaian Medis
Vol. 11 No. 2 (2026): December:
DOI : https://doi.org/10.21070/acopen.11.2026.13906
Published : Jul 15, 2026

Lerinda Salma Trinisa (1), Dira Ernawati (2), Isna Nugraha (3)

(1) Program Studi Teknik Industri, Universitas Pembangunan Nasional “Veteran” Jawa Timur, Indonesia
(2) Program Studi Teknik Industri, Universitas Pembangunan Nasional “Veteran” Jawa Timur, Indonesia
(3) Program Studi Teknik Industri, Universitas Pembangunan Nasional “Veteran” Jawa Timur, Indonesia
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Abstract:

General Background: Efficient supply chain and production systems are essential for minimizing non-value-added activities and improving resource utilization in manufacturing operations. Specific Background: PT XYZ, a medical apparel manufacturer producing surgical gowns, still experienced waste in its production flow from raw material receiving to finished products. Knowledge Gap: Previous lean studies mostly focused on internal production processes and had not extensively integrated supply chain analysis, Value Stream Mapping, and systematic continuous improvement in the medical apparel industry. Aims: This study aimed to identify waste in the surgical gown production process and propose improvements using Lean Supply Chain Management, Value Stream Mapping, and Kaizen 5W+1H. Results: Current mapping showed a total lead time of 350 minutes, with 115 minutes of value-added activities, 125 minutes of non-value-added activities, 110 minutes of necessary non-value-added activities, and Process Cycle Efficiency of 32.86%. The highest critical wastes were defect with a weight of 3.83, overprocessing at 3.50, and waiting at 3.33. Simulation of proposed improvements eliminated five non-value-added activities, reduced production time from 350 to 300 minutes, increased efficiency from 32.86% to 38.33%, and achieved 50 minutes of time saving or 14.29%. Novelty: This study integrates Lean Supply Chain Management, VSM, VALSAT, PAM, fishbone analysis, and Kaizen 5W+1H in surgical gown manufacturing. Implications: The proposed model can help PT XYZ reduce waste, improve workflow efficiency, and support continuous improvement in medical apparel manufacturing.


Highlights:



  • Five non-value-added activities were eliminated through simulation.

  • Process Cycle Efficiency rose from 32.86% to 38.33%.

  • Defect, overprocessing, and waiting became the main priorities.


Keywords: Kaizen, Lean Supply Chain Management, Value Stream Mapping, Waste

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