The Implementation of Lean Automation and Kitting System Integration to Improve Assembly Line Efficiency in the Automotive Industry

Abstract

The rapid development of the automotive industry in Indonesia has intensified global competition, requiring manufacturers to continuously improve production efficiency and operational performance. However, inefficiencies remain in the final-2 assembly line, where excessive non–value-added activities such as unnecessary operator movement and part searching contribute to a high cycle time and low Process Cycle Efficiency (PCE). This study aims to reduce production inefficiencies by identifying and eliminating waste in the assembly process. The research employs the Value Stream Mapping (VSM) method to analyze the current production flow and determine sources of non–value-added activities. Based on the analysis, improvement initiatives were implemented through the integration of Lean Automation and the Kitting System. Lean Automation reduces manual repetitive tasks and minimizes operational waste, while the Kitting System organizes and supplies components to the assembly line in a structured and timely manner. The implementation results show a significant improvement in production performance, where the cycle time decreased from 160.08 seconds to 88.08 seconds. Consequently, Process Cycle Efficiency increased from 53.03% to 57.89%. These findings demonstrate that integrating VSM with lean automation and structured kitting effectively enhances production efficiency and supports the development of a more competitive automotive manufacturing system.