Analysis of Production Process Improvement on Automatic Bolt Forming Machine Using Value Stream Mapping and FMEA Approach
DOI:
https://doi.org/10.63142/ijeti.v1i2.381Keywords:
Value Stream Mapping, FMEA, Lean Manufacturing, Production EfficiencyAbstract
This study aims to analyze the production efficiency of an automatic bolt forming machine at PT XYZ using the Value Stream Mapping (VSM) and Failure Mode and Effect Analysis (FMEA) approaches. The Lean Manufacturing concept was applied to identify non-value-added activities and potential failures affecting production quality. Data were collected through direct observation, cycle time measurement, and interviews with operators and supervisors over a three-month period. The VSM results indicate that the total process time of 20,304 seconds consists of 75.64% value-added activities, 11.97% non-value-added activities, and 12.40% necessary but non-value-added activities. These findings show that efficiency improvements are still possible by minimizing non-value-adding processes. The FMEA analysis revealed the highest Risk Priority Number (RPN) of 147, occurring in the forming stage with failures such as improper heading, inaccurate trimming, and die damage. The study concludes that combining VSM and FMEA provides an effective framework for assessing process performance and determining improvement priorities to enhance efficiency and reduce product defects
References
Aleksić, A., Tadić, D., Komatina, N., & Nestić, S. (2025). Failure Mode and Effects Analysis Integrated with Multi-Attribute Decision-Making Methods Under Uncertainty: A Systematic Literature Review. In Mathematics (Vol. 13, Issue 13). Multidisciplinary Digital Publishing Institute (MDPI). https://doi.org/10.3390/math13132216
Alruqi, M., Baumers, M., Branson, D., & Farndon, R. (2021). A Structured Approach for Synchronising the Applications of Failure Mode and Effects Analysis. Management Systems in Production Engineering, 29(3), 165–177. https://doi.org/10.2478/mspe-2021-0021
El-Awady, S. M. M. (2023). Overview of Failure Mode and Effects Analysis (FMEA): A Patient Safety Tool. Global Journal on Quality and Safety in Healthcare, 6(1), 24–26. https://doi.org/10.36401/JQSH-23-X2
García Aguirre, P. A., Perez-Dominugez, L., Luviano-Cruz, D., Romero-López, R., & Leon-Castro, E. (2022). PFDA-FMEA-VSM Application for Outsourcing Risk Analysis. https://doi.org/10.20944/preprints202201.0002.v1
Gomaa, A. H. (2025). Enhancing Lean Performance through TPM–VSM Integration: A Case Study in Spare Parts Production. International Journal of Darshan Institute on Engineering Research and Emerging Technologies, 14(1), 1–14. https://doi.org/10.32692/ijdi-eret/14.1.2025.2501
Horsthofer-Rauch, J., Schumann, M., Milde, M., Vernim, S., & Reinhart, G. (2022). Digitalized value stream mapping: Review and outlook. Procedia CIRP, 112, 244–249. https://doi.org/10.1016/j.procir.2022.09.079
Iskandar, R., & Singgih, M. L. (2023). Lean and Green Value Stream Mapping: Case Study of an East Java Furniture Factory (pp. 114–131). https://doi.org/10.2991/978-94-6463-288-0_12
Oliveira, M., Batista, S., Reis, D., Veroneze, G., & Maciel, R. (2019). Application of fmea for improvement in the manufacturing process of mobile phones in a factory of the industrial pole of Manaus. International Journal for Quality Research, 13(4), 1021–1036. https://doi.org/10.24874/IJQR13.04-18
Salwin, M., Pszczółkowska, K., Pałęga, M., & Kraslawski, A. (2023a). Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools. Energies, 16(21). https://doi.org/10.3390/en16217292
Salwin, M., Pszczółkowska, K., Pałęga, M., & Kraslawski, A. (2023b). Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools. Energies, 16(21). https://doi.org/10.3390/en16217292
Singh, M., Singh, E. G., & Garg, E. J. (n.d.). Value Stream Mapping: A Case Study of Fastener Industry. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN, 12(5), 7–10. https://doi.org/10.9790/1684-12530710
Suhardi, B., Hermas Putri K.S, M., & Jauhari, W. A. (2020). Implementation of value stream mapping to reduce waste in a textile products industry. Cogent Engineering, 7(1). https://doi.org/10.1080/23311916.2020.1842148
Varghese, N. (2025). Enhance Productivity in Garment Industry Through VSM and FMEA Approaches. In IJISET-International Journal of Innovative Science, Engineering & Technology (Vol. 12). www.ijiset.com
Wang, C. N., Vo, T. T. B. C., Chung, Y. C., Amer, Y., & Truc Doan, L. T. (2024). Improvement of Manufacturing Process Based on Value Stream Mapping: A Case Study. EMJ - Engineering Management Journal, 36(3), 300–318. https://doi.org/10.1080/10429247.2023.2265793
Zuraidah Rasi, R. R., Tun Hussein Onn Malaysia, U., Pahat, B., Rohana Abdullah, M., Omar, N., Tuah Jaya, H., Suhana Mohamed, M., Teknologi MARA, U., Johor Bahru, K., Heman, J., Aman, K., & Bahru, J. (n.d.). Value Stream Mapping using Simulation at Metal Manufacturing Industry.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Fiky Two Nando, Davin Danny Ivander, Desti Sagita Sharren, Christoforus Yudhistira, Hilbram Remadaniel, Mashudan As Shidiq, A.Anditha Sari (Author)
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
How to Cite
