Current State of Production Process

Oct 13, 2025 by recoveryshake.com 129 views

Introduction

The efficiency of the production process is a crucial factor in producing high-quality products. One of the key indicators of efficiency is the time needed to complete the production process. This study examines the application of the GERT (Graphical Evaluation and Review Technique) and VSM (Value Stream Mapping) methods at PT Morawa Electric Transbuana to minimize production time by eliminating non-value added activities.

Current State of Production Process

The initial condition of the production process at PT Morawa Electric Transbuana was assessed through a value stream mapping (VSM) exercise. The results showed that the production process had a value-added percentage of 21% (4.84 days) and non-value added activities accounted for 79% (18.20 days). The production waiting time (production lead time) in the initial conditions reached 23.10 days, with a processing time of 6963.07 minutes.

Value Stream Mapping (VSM)

Value Stream Mapping (VSM) is a powerful tool used to visualize the flow of materials and information in a production process. It helps to identify areas of waste and inefficiency, and provides a clear picture of the current state of the production process. In this study, the VSM exercise revealed that the production process at PT Morawa Electric Transbuana was plagued by non-value added activities, which accounted for a significant portion of the total production time.

GERT (Graphical Evaluation and Review Technique)

The GERT method is a powerful tool used to analyze and improve the efficiency of complex systems. It provides a graphical representation of the system, allowing for the identification of bottlenecks and areas of waste. In this study, the GERT method was used to analyze the production process at PT Morawa Electric Transbuana and identify areas for improvement.

Application of GERT and VSM Methods

Through the application of the GERT and VSM methods, the research team was able to identify non-value added activities and design a new production path pattern. The proposed condition (Future State Map) showed a significant reduction in production waiting time, from 23.10 days to 17.35 days, with a processing time of 1950.75 minutes. The decline in waiting time for production reached 5.75 days (24.89%), with a new layout design that was more efficient.

Benefits of GERT and VSM Methods

The application of the GERT and VSM methods provides several advantages, including:

Identification and Elimination of Non-Value Added Activities

This method makes it possible to identify activities that do not provide added value to the product and eliminate them from the production process. This reduces the waste of time, resources, and production costs.

Increasing the Efficiency of Production Flow

By mapping the value of values (value streams), the research team can identify obstacles and bottlenecks in production flow. This makes it possible to redesign more efficient and effective production flow.

Layout Optimization

The GERT and VSM methods help in optimizing the layout of production facilities to minimize the distance and time of material transfer. This increases operational efficiency and reduces production time.

Increased Visibility of the Process

Mapping VSM provides a clear picture of the whole production process, facilitating the identification of areas that require improvement and optimization.

Conclusion

This study demonstrates the effectiveness of the GERT and VSM methods in optimizing production time by eliminating non-value added activities. The application of these methods at PT Morawa Electric Transbuana resulted in a significant reduction in production waiting time and processing time. The benefits of the GERT and VSM methods are numerous, including the identification and elimination of non-value added activities, increasing the efficiency of production flow, layout optimization, and increased visibility of the process.

Recommendations

Based on the findings of this study, the following recommendations are made:

Implement the GERT and VSM methods in other production processes to identify areas for improvement and optimize production time.
Continuously monitor and evaluate the production process to ensure that the improvements made are sustained over time.
Provide training and education to production staff on the GERT and VSM methods to ensure that they are able to effectively apply these tools in their work.

Limitations of the Study

This study has several limitations, including:

Limited scope: The study was limited to a single production process at PT Morawa Electric Transbuana.
Data collection: The data used in this study was collected through a single VSM exercise and may not be representative of the entire production process.
Generalizability: The findings of this study may not be generalizable to other production processes or industries.

Future Research Directions

Future research should focus on:

Applying the GERT and VSM methods in other production processes to identify areas for improvement and optimize production time.
Evaluating the effectiveness of the GERT and VSM methods in different production environments.
Developing new tools and techniques to support the application of the GERT and VSM methods.

Conclusion

In conclusion, this study demonstrates the effectiveness of the GERT and VSM methods in optimizing production time by eliminating non-value added activities. The application of these methods at PT Morawa Electric Transbuana resulted in a significant reduction in production waiting time and processing time. The benefits of the GERT and VSM methods are numerous, and their application can have a significant impact on the efficiency and productivity of production processes.

Introduction

The GERT (Graphical Evaluation and Review Technique) and VSM (Value Stream Mapping) methods have been widely used in various industries to optimize production time and improve efficiency. However, there are still many questions and concerns about the application of these methods. In this article, we will address some of the frequently asked questions (FAQs) on the application of GERT and VSM methods.

Q1: What is the difference between GERT and VSM methods?

A1: The GERT method is a powerful tool used to analyze and improve the efficiency of complex systems, while the VSM method is a tool used to visualize the flow of materials and information in a production process. While both methods are used to identify areas for improvement, the GERT method is more focused on the analysis of complex systems, while the VSM method is more focused on the visualization of the production process.

Q2: How do I choose between GERT and VSM methods?

A2: The choice between GERT and VSM methods depends on the specific needs of your production process. If you are dealing with a complex system that requires analysis and improvement, the GERT method may be more suitable. If you are looking to visualize the flow of materials and information in your production process, the VSM method may be more suitable.

Q3: What are the benefits of using GERT and VSM methods?

A3: The benefits of using GERT and VSM methods include:

Identification and elimination of non-value added activities: These methods help to identify activities that do not provide added value to the product and eliminate them from the production process.
Increasing the efficiency of production flow: By mapping the value of values (value streams), the research team can identify obstacles and bottlenecks in production flow and redesign more efficient and effective production flow.
Layout optimization: The GERT and VSM methods help in optimizing the layout of production facilities to minimize the distance and time of material transfer.
Increased visibility of the process: Mapping VSM provides a clear picture of the whole production process, facilitating the identification of areas that require improvement and optimization.

Q4: How do I apply the GERT and VSM methods?

A4: The application of the GERT and VSM methods involves the following steps:

Define the scope of the project: Identify the specific area of the production process that requires improvement.
Gather data: Collect data on the current state of the production process, including production times, material transfer times, and other relevant metrics.
Analyze the data: Use the GERT and VSM methods to analyze the data and identify areas for improvement.
Design a new production path: Based on the analysis, design a new production path that eliminates non-value added activities and optimizes production flow.
Implement the new production path: Implement the new production path and monitor its effectiveness.

Q5: What are the limitations of the GERT and VSM methods?

A5: The limitations of the GERT and VSM methods include:

Limited scope: The GERT and VSM methods are typically used to analyze and improve specific areas of the production process, rather than the entire process.
Data collection: The data used in the GERT and VSM methods must be accurate and reliable, which can be challenging to collect.
Generalizability: The findings of the GERT and VSM methods may not be generalizable to other production processes or industries.

Q6: How do I measure the effectiveness of the GERT and VSM methods?

A6: The effectiveness of the GERT and VSM methods can be measured by tracking key performance indicators (KPIs) such as:

Production time: Measure the time it takes to complete the production process.
Material transfer time: Measure the time it takes to transfer materials between different stages of the production process.
Production cost: Measure the cost of producing a unit of product.
Customer satisfaction: Measure the level of satisfaction of customers with the product.

Conclusion

In conclusion, the GERT and VSM methods are powerful tools used to optimize production time and improve efficiency. By understanding the benefits, limitations, and application of these methods, you can make informed decisions about how to apply them in your production process.