Lean DMAIC and SMED Implementation to Enhance Aerospace Component Production at PT XYZ West Java

Aerospace manufacturing demands lean operational to remain globally competitive. This research investigates production inefficiencies within “X Machine Group” at PT XYZ, a critical area featuring 24 CNC units producing aerospace components. Preliminary observations indicated process bottlenecks, characterized by high work-in-process (WIP) accumulation and excessive lead times. The study utilizes the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. Value Stream Mapping (VSM) focused on high volume parts revealing that while processing and cycle times were relatively stable, the changeover (C/O) time was source of inefficiency. Fishbone and 6S audit further identified that delays were systemic, rooted in non-standardized changeover, uneven operator skills, and a lack of visual management for preparation. The study proposes a comprehensive improvement centered on the Single Minute Exchange of Dies (SMED) and time study method. By converting “Internal Process” activities such as tool preparation and information retrieval into “External Process” tasks performed while machines are running, the research demonstrates a projected reduction in changeover times. Future state time studies indicate consistent efficiency, with changeover times decreasing by 18% to 19% across the analyzed part. PN-001 exhibited a changeover time of 6.1 hours, become 5 hours after improvement implemented. The integration of Smart Manufacturing solutions is proposed, including IoT based OEE dashboards and RFID-enabled WIP tracking to eliminate information lag and enhance traceability. These processes collectively confirm that implementation of 5S principles and SMED identification can effectively reduce changeover time and enhance process efficiency.