Kaizen Implementation Using 5S To Reduce Waste In Stainless Steel Rack Manufacturing

Abstract

This research focuses on the implementation of Kaizen using the 5S method to reduce waste in the production process of stainless steel racks at CV Brinj Utama Samudra. In the Industrial context, manufacturing companies face intense competition, which demands high-quality products and optimized production efficiency by minimizing non-value-added activities (NVAs) such as waiting time, inefficient movement operators, and welding defects. Initial observations of waste identification include waiting time between work stations, inefficient material sourcing, and suboptimal cutting and welding processes, which increase operational costs and decrease product quality.

The purpose of this study was to implement Kaizen with 5S to reduce waste, manage stainless steel waste, and maintain production output by applying Kaizen to machines to achieve maximum output and minimize waste. The research methods included a literature review, initial observations of the production area, data collection using checklists and stopwatch measurements, waste analysis, and the implementation of 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke).

Initial findings indicate that the implementation of 5S improves work area order, reduces wasteful movement and waiting time, and increases productivity. This study provides practical recommendations for sustainable waste reduction, supporting the competitiveness of CV Brinj Utama Samudra. Limitations include a focus on cutting, welding, assembly, and finishing processes, with the evaluation based on available company data. Keywords: Kaizen, 5S, Waste Reduction, Stainless Steel Racks