International Journal of Engineering Research and Advanced Technology (IJERAT) E-ISSN : 2454-6135 DOI: 10.31695/IJERAT.2020.3657 Volume.6, Issue 10 October -2020 www.ijerat.com Page 49 Licensed Under Creative Commons Attribution CC BY Reduction of Cycle Time in Vehicle Engine Assembly Line Using Karakuri Kaizen Alur Pogowonto 1 , Uly Amrina 2 1-2 Industrial Engineering Department Faculty of Engineering, Universitas Mercu Buana Jl. Raya Meruya Selatan, Kembangan, Jakarta 11650 Indonesia _______________________________________________________________________________________ ABSTRACT Just In Time (JIT) based automotive manufacturing companies use the takt time and cycle time as indicators of their manufacturing performance. This study explores the vehicle engine assembly line for Station 2 Cylinder Block Products, which has a cycle time of 184 seconds, while the company targets a 180 second for takt time. Though ideally, the cycle time should not exceed the takt time. This research aims to identify the Non-Value Added (NVA) activities in Station 2 and minimize them with Karakuri Kaizen. The results of the Process Activity Mapping (PAM) show that Station 2 Cylinder Block has 16 Value Added (VA) activities, 19 Necessary Non-Value Added (NNVA) activities, and 7 Non-Value Added (NVA) activities with a manufacturing cycle effectiveness (MCE) 78%. Based on the activity mapping, the researchers find the primary causes and designed a proposed improvement using the Karakuri Kaizen method to reduce two NVA activities. The company can speed up the cycle time at Station 2 Cylinder Block to 180 seconds and the MCE to 80% by implementing Karakuri Kaizen. Key Words: Cycle Time, Non-Value Added Activity, Process Activity, Mapping, Karakuri Kaizen, Vehicle Engine. ______________________________________________________________________________________________ 1. INTRODUCTION The four-wheeled vehicle manufacturing industry develops from time to time because of the increasing demand every year. Gaikindo stated that the number of four-wheeled vehicle production in Indonesia has increased by 244,923 units from 2015 to 2019 [1]. The increase in the number of car production drives the vehicle engine industry's growth and requires every vehicle engine Manufacturing company to compete and always improve productivity performance while controlling production costs. It also encourages several automotive manufacturing companies to use the Toyota Production System (TPS) as their production system. TPS is a method that helps product manufacturers to achieve better profits [2]. TPS aims to provide products with the best quality, lowest cost, and shortest production lead time by eliminating waste during production. TPS consists of two main pillars, namely Just In Time (JIT) and Jidoka supported by Kaizen, Work Standardization, Heijunka, PDCA, 5S, Total Productive Maintenance (TPM), and other manufacturing strategies as the foundation [3]. Companies that use JIT have two main times, namely the tact time and the cycle time, to calculate and measure the timeframe of various processes and the average time per item. According to Imai, takt time is the available production time divided by the number of units demanded by consumers [4]. Takt time is a theoretical value that refers to how long it takes to complete one product unit in each process. Meanwhile, cycle time is the real-time needed for operators to complete their operational tasks. The basic idea in JIT is to make the cycle time as close to the takt time as possible but not to exceed the takt time. As the research subject, the vehicle engine company has two parts in the production division, namely machining and assembly line. The assembly line has a takt time of 3.0 minutes or 180 seconds with 17 stations. The assembly line consists of the Sub Line, which works on the engine's core parts with 11 stations, and the Main Line, which works on the exterior or accessories for car engines with six stations.