Enhancing Brick Production Efficiency through the Implementation of Lean Manufacturing using the Waste Assessment Model (WAM)

Abstract

Competition in the manufacturing sector requires companies of all sizes to
maintain efficient production performance and eliminate waste. Lean
Manufacturing serves as a strategic approach to minimize waste and enhance
process efficiency. UD Surya, a small-scale enterprise producing concrete bricks,
faces various challenges related to production capacity and effectiveness,
particularly involving wastes such as overproduction, defects, inventory,
processing, waiting, transportation, and motion. This study aims to improve the
efficiency of brick production through the implementation of Lean
Manufacturing using the Waste Assessment Model (WAM). The WAM method
is employed to quantitatively identify waste levels, supported by Pareto diagram
analysis to determine priority issues. The results indicate that several categories
of waste exceed the 15% threshold, requiring immediate corrective actions to
prevent further losses and improve production efficiency. These findings
demonstrate that the application of Lean Manufacturing based on WAM is
effective in identifying critical waste and provides a strong foundation for
continuous improvement strategies in the brick production process at UD Surya.