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The Company IM is a manufacturing company that produces two-wheeled automotive spare parts. One of the products currently being supplied to several two-wheeled customers is the disc brake, rear sprocket, and drive sprocket. The opportunity to increase production output adjusted to high customer demand can be done by reducing waste activities. Therefore, an approach with a lean six sigma approach is needed using the integration method of DMAIC (Define, Measure, Analyze, Improve, and Control), VSM (Value Stream Mapping), and VALSAT. This study aims to reduce production waste and reduce cycle time, affecting increasing production output to balance according to customer needs. Waste identification is explained in the Define stage at DMAIC using a big mapping image in Value Stream Mapping. A more in-depth analysis is carried out using the VALSAT tools at the Analyze stage supported by WRM and WAQ questionnaire data. The Analyze stage was then carried out by analyze using the FMEA method. Control is carried out by standardization and outreach to employees. This study aims to identify and reduce the waste in the production area, especially line-cutting disks. Based on the integration results of lean six sigma with the DMAIC, VSM, and VALSAT methods, the efficiency is obtained from 72% to 96%.

international journal of scientific advances

Integration of DMAIC, VSM and Valsat to Reduce Waste in Disk Brake Cutting Process Using DMAIC, VSM and Valsat Method Approach (Case Study: Company IM)