Analisa Peningkatan Produktivitas Dan Efisiensi Kerja Dengan Penerapan Kaizen (Studi kasus : PT Beiersdorf Indonesia PC Malang)

Ayuningtyas, Respati (2014) Analisa Peningkatan Produktivitas Dan Efisiensi Kerja Dengan Penerapan Kaizen (Studi kasus : PT Beiersdorf Indonesia PC Malang). Sarjana thesis, Universitas Brawijaya.

Abstract

PT Beiersdorf Indonesia merupakan perusahaan multinasional yang memproduksi Nivea dan Hansaplast. Kualitas merupakan faktor yang mendasar bagi konsumen dalam memilih produk yang akan dibeli. Namun, jaminan kualitas yang baik ternyata belum cukup apabila tidak diimbangi dengan produktivitas yang baik. Pada produksi Hansaplast di area manual packing untuk produk HP ASS WR 40 ternyata belum dilakukan standarisasi metode kerja dan adanya permasalahan layout produksi yang belum efisien. Hal ini mengakibatkan output produksi yang tidak sesuai dengan target yang ditetapkan. Hasil output produksi aktual sebesar 147 shipping carton sedangkan target yang ditetapkan adalah 179 shipping carton. Selain itu juga terjadi bottle neck pada proses produksi yang disebabkan oleh perbedaan persepsi antar operator dalam menyelesaikankan pekerjaannya. Permasalahan yang terjadi pada proses produksi HP ASS WR 40 di area manual packing dapat diperbaiki dengan melakukan penerapan Kaizen. Penerapan Kaizen dilakukan untuk membuat standarisasi elemen kerja yang meliputi perbaikan layout produksi dan penentuan waktu baku agar dapat mengukur adanya peningkatan produktifitas dan efisiensi kerja produk HP ASS WR 40. Dalam melakukan Kaizen, dilakukan beberapa metode untuk mendukung jalannya penelitian. Langkah pertama dalam Kaizen adalah dengan menerapkan siklus plan-do-check-action (PDCA) sebagai sarana untuk menjamin terlaksananya kesinambungan dari Kaizen. Tahap awal yang dilakukan adalah mengidentifikasi waktu baku aktual dengan metode jam henti. Setelah itu dilakukan keseimbangan lini untuk meminimumkan banyaknya operator dan waktu menganggur. Selanjutnya mengidentifikasi gerakan-gerakan kerja operator untuk menentukan gerakan yang efisien dengan peta tangan kiri dan tangan kanan. Hasil penelitian menunjukkan adanya peningkatan efisiensi kerja yang dapat dilihat dari lama waktu baku sebelum dilakukan perbaikan sebesar 60.49 detik dan hasil dari estimasi perbaikan sebesar 44.63 detik. Selain itu metode keseimbangan lini terpilih adalah LCR karena memiliki nilai efisiensi terbesar yaitu 95% dan nilai Smoothness index paling rendah yaitu 2.4. Selanjutnya dilakukan perbaikan berdasarkan metode LCR. Dari hasil estimasi perbaikan didapatkan nilai efisiensi sebesar 80% dan nilai Smoothness index 6.45. Hal ini menunjukkan bahwa proses perbaikan lebih efisien dan lebih lancar daripada sebelum dilakukan perbaikan dengan nilai efisiensi 60% dan Smoothness Index 20.3. Peningkatan produktivitas dalam penelitian ini terlihat dari meningkatnya output produksi dari 147 shipping carton menjadi 187 shipping carton.

English Abstract

PT Beiersdorf Indonesia is a multinational company that producing Nivea and Hansaplast. Quality is a fundamental factor for consumers when selecting products. However, a good quality assurance was not enough when it is not balanced with good productivity. The problem on Hansaplast production there is no standard that makes the production layout has not been efficient in manual packing area. This condition causes the production target was not reached. The result of actual production output was 147 shipping cartons, while the target is 179 shipping cartons. Another problem is bottleneck in the production process due to different perception between operators when finishing their job. The problems that occurred in the production of HP ASS WR 40 can be improved with Kaizen implementation. Kaizen aims to standardize the working elements which include improvement for production layout and determining the standard time to measure an increase in productivity and work efficiency for production. In Kaizen, there are several methods to support this research. The first step is the implementation of plan-do-check-action (PDCA) cycle to ensure the implementation of the sustainability of Kaizen. This step begins with identifying the actual standard time with stopwatch time study. The next step is to reduce the number of operators and idle time using line balancing method. The following step is to identify the operator’s movement to determine the efficient movements using left right hand chart. The results showed that there is a reduction in standard time from the actual condition of 60.49 seconds to 44.63 seconds after improvement. Largest Candidate Rule (LCR) method was chosen from the comparison of several line balancing methods due to the highest efficiency of 95% and the lowest smoothness index value of 2.4. The next step is to improve operator’s work according to the LCR method. The results shows that the efficiency is 80% and smoothness index value is 6.45. This condition indicates that the improvement is more efficient and more smoothly than before with the efficiency was 60% and the smoothness index value was 20.3. Furthermore, the increasing of productivity can be shown from the actual production output 147 shipping carton to 187 shipping carton per day after improvement.

Item Type: Thesis (Sarjana)
Identification Number: SKR/FT/2014/111/051401293
Subjects: 600 Technology (Applied sciences) > 670 Manufacturing
Depositing User: Hasbi
Date Deposited: 24 Feb 2014 13:29
Last Modified: 21 Oct 2021 12:35
URI: http://repository.ub.ac.id/id/eprint/142372
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