Manufacturing efficiency is central to industrial competitiveness
In modern manufacturing, companies must deliver high-quality products quickly while keeping costs under control. Industries producing transformer components face particular challenges because precision welding, assembly, and testing are essential to prevent leakage and structural failure.
Production inefficiencies such as waiting time, rework, and workflow imbalance can significantly increase operational costs. As global competition intensifies, manufacturers increasingly adopt lean production strategies to minimize waste while maintaining product reliability and customer trust.
How the research was conducted
The researchers combined field observation and production data analysis to examine the transformer tank fabrication process at PT. Gemilang Jaya Prima Perkasa. The study focused on key stages including welding, assembly, non-destructive testing, finishing, and quality control.
Production flows were mapped using Value Stream Mapping to distinguish activities that add value from those that do not. Root causes of defects were investigated using cause-and-effect analysis, and a redesigned production flow was proposed to represent a more efficient future system. This mixed-method approach allowed the researchers to capture both operational data and organizational practices influencing efficiency.
Key findings from the study
The results reveal several major insights into manufacturing performance:
- Leakage defects are the largest contributor to overall production defects.
- Leakage, welding spatter, and dimensional errors account for more than 70 percent of defects.
- The welding stage contains the highest proportion of non-value-added time, exceeding 62 percent of total process time.
- The production system operates at roughly a 3–3.35 sigma quality level, indicating substantial room for improvement.
- Bottlenecks in welding reduce output and extend lead time across the production line.
Cycle-time data also show that welding consumes significantly more processing time than other stages, making it the most critical target for improvement.
Root causes extend beyond technical issues
The analysis demonstrates that production inefficiencies are not solely technical. Instead, they arise from a combination of organizational and operational factors.
These include inconsistent operator skills, the absence of standardized welding parameters, unstable machine performance, material inconsistencies, limited inspection procedures, and suboptimal working conditions such as lighting. Additionally, quality inspection often occurs only at the final stage, allowing defective products to move through multiple steps before detection, increasing rework time and cost.
This pattern shows that manufacturing performance depends not only on equipment but also on workflow design, training, and quality management systems.
Implications for industry and management
The study offers several practical lessons for manufacturers seeking to improve competitiveness.
First, lean manufacturing should become a long-term organizational culture rather than a short-term improvement project. Continuous evaluation of workflow efficiency can help companies maintain productivity gains.
Second, standardized operating procedures—particularly in welding and inspection—can reduce variability and improve consistency. Regular operator training and certification programs are also recommended to strengthen technical skills and reduce defects.
Third, the proposed Future State Value Stream Mapping demonstrates how production planning tools can help managers improve capacity planning, streamline process flow, and ensure timely delivery to customers.
Together, these measures show how structured process analysis can translate into measurable performance improvements across manufacturing systems.
Academic insight from the authors
Faiz Dzaky Himamul Murtafa of Universitas Mercu Buana emphasizes that production waste often originates from weak process management rather than individual mistakes. He argues that systematic lean implementation allows companies to eliminate non-value-added activities while improving product reliability and operational sustainability.
Author profiles
Faiz Dzaky Himamul Murtafa is a researcher in operations management and industrial efficiency at Universitas Mercu Buana, focusing on lean manufacturing, production optimization, and quality control systems.
Dewi Nusraningrum is a senior academic at Universitas Mercu Buana specializing in organizational performance, operations management, and industrial strategy.
Their research explores how manufacturing firms can improve efficiency, quality, and competitiveness through systematic process improvement.
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