5 Why Analysis dan Implementasi Dies Multicavity dalam Peningkatan Produktivitas dan Efisiensi Tenaga Kerja pada Proses Pembuatan Lubang Pipa di Perusahaan Otomotif Indonesia

Ahmad Syafrudin; Muhammad Fahmi Romadhan; Fahru Radju Dwinata; Naufal Luthfi Barizki; Yudi Prastyo

doi:10.61722/jinu.v3i5.10930

Authors

Ahmad Syafrudin Universitas Pelita Bangsa
Muhammad Fahmi Romadhan Universitas Pelita Bangsa
Fahru Radju Dwinata Universitas Pelita Bangsa
Naufal Luthfi Barizki Universitas Pelita Bangsa
Yudi Prastyo Universitas Pelita Bangsa

DOI:

https://doi.org/10.61722/jinu.v3i5.10930

Keywords:

5 Why Analysis, Multicavity Dies, Bottleneck, Productivity, Labor Efficiency, Line Boring

Abstract

Productivity is a primary indicator of manufacturing system success. In the type 3.2 pipe hole-making process at the line boring station of an Indonesian automotive company, a long drilling process problem was identified due to limited hole-making capacity and a bottleneck at the reaming stage, resulting in suboptimal finish good output. This study aims to identify the root causes using the 5 Why Analysis method and to analyze the effect of implementing multicavity dies on productivity and labor efficiency. A descriptive quantitative approach with a before-after comparison design was employed. Before data were collected over 63 effective working days (Juni-August 2025), and after data over 64 effective working days (September-November 2025). The 5 Why Analysis identified three root cause categories: machine (drilling produced only 1 cavity per stroke and generated burrs requiring reaming), safety (safety cover obstructed visibility and caused non-ergonomic work posture), and man (separated workflow required more operators). A 4-cavity multicavity dies was implemented, consolidating drilling and reaming into a single press dies operation. Results showed average finish good output increased from 3,869 to 5,204 pcs/day (+34.5%), while operators were reduced from 3 to 2 (33.3% labor efficiency). Multicavity dies effectively eliminated the bottleneck and enhanced overall system capacity

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