Tiarso, Ferdian Elvis and Ihwan Hamdala, , ST., MT and Mochamad Choiri, Ir. , MT (2014) Upaya Pengurangan Waste Di Bagian Pre Spinning Dengan Pendekatan Lean Manufacturing (Studi Kasus Di Pt Isn Unit Patal Lawang). Sarjana thesis, Universitas Brawijaya.
Abstract
PT. Industri Sandang Nusantara (ISN) unit Patal Lawang merupakan perusahaan yang memproduksi benang tenun. Proses produksi dibagi menjadi 4 bagian yaitu Pre Opening, Pre Spinning, Spinning , dan Finishing. Di bagian Pre Spinning ditemukan beberapa waste antara lain rework process , dan defect . Untuk mengetahui waste lain yang terjadi, maka diperlukan suatu identifikasi yang lebih detail. Untuk itu diperlukan suatu pendekatan yang fokus terhadap penurunan waste yaitu Lean Manufacturing. Pada pendekatan Lean Manufacturing , digunakan tool untuk mengidentifikasi waste yaitu Value Stream Mapping (VSM). Selain tool tersebut, juga digunakan beberapa tools untuk melengkapi identifikasi waste yaitu Process Activity Mapping (PAM), Analitycal Hierarchy Process (AHP), dan Fishbone Diagram . VSM digunakan untuk memetakan aliran proses produksi benang yang terdiri dari aliran informasi dan aliran fisik beserta waktunya. PAM digunakan untuk mengetahui aktivitas apa saja yang termasuk ke dalam non value added . Dalam tabel PAM, non value added activity dibagi menjadi non value added activity (NVA) dan necessary but non value added activity (NNVA). AHP digunakan untuk menentukan prioritas dari 7 tipe waste . Dari 7 tipe waste , didapatkan 3 tipe waste yang memiliki tingkat kepentingan tertinggi menurut perusahaan untuk dianalisis dan dicari penyebab terjadinya dengan menggunakan diagram fishbone . Setelah penyebab waste diketahui, maka selanjutnya dicari rekomendasi perbaikan untuk mengurangi atau menghilangkan waste tersebut. Hasil identifikasi VSM dan PAM menunjukkan bahwa total non value added time dalam aliran nilai proses di bagian Pre Spinning adalah 43,426 menit. Pembobotan dengan AHP menghasilkan 3 tipe waste yang memiliki nilai kepentingan tertinggi yaitu waiting , defect , dan excessive transportation . Waiting yang teridentifikasi antara lain mesin Drawing Breaker mengalami waiting , mesin Carding menunggu selama 0,05 menit setiap memproses 1 Lap dan operator Drawing Breaker menunggu selama 0,369 menit setiap memproses 16 can Sliver . Defect yang teridentifikasi antara lain defect pada produk Lap , Sliver , dan Roving . Rata-rata defect total yang terjadi berdasarkan data bulan November 2012 sampai November 2013 adalah 3355,25 kg per bulan atau 5,26 % dari rata-rata produksi per bulan. Excessive transportation yang teridentifikasi antara lain transportasi dari area Carding ke area Drawing selama 3,14 menit, dari Drawing Breaker ke Drawing Finisher selama 1,344 menit, dan dari area Drawing ke area Speed selama 19,858 menit. Transportasi tersebut dilakukan secara bolak-balik. Usulan rekomendasi perbaikan antara lain, menambah jumlah mesin Carding sebanyak 20 mesin, meningkatkan kapasitas hand truck , penambahan operator sementara dari bagian maintenance untuk membantu proses transportasi di area Drawing, penghapusan proses pembungkusan Lap, dan tambahan waktu maintenance . Jika rekomendasi perbaikan dilakukan, maka dapat meminimasi waktu produksi per bulan dengan estimasi selama 882,42 menit. Waktu tersebut dapat dialokasikan untuk aktivitas value added , sehingga dapat meningkatkan jumlah produksi per bulan.
English Abstract
PT Industri Sandang Nusantara (ISN) Patal Lawang is a producing yarn. Production process is divided into 4 parts: Pre Opening, Pre Spinning, Spinning, and Finishing. Some waste found in Pre Spinning, include rework process, and defect. Detail identification is needed to find other waste. For that, an approach that focuses on reducing waste is needed. That approach is Lean Manufacturing. Based on Lean Manufacturing approach, used tool to identify waste that is Value Stream Mapping (VSM). Beside that, also used several tools to complete the identification of waste, namely Process Activity Mapping (PAM), Analytical Hierarchy Process (AHP), and the Fishbone Diagram. VSM is used to mapping the flow of yarn production process consists of the flow of information and physical flows at a given time. PAM is used to determine what activities are included in non-value added. PAM divide non-value added activity into non-value added activity (NVA) and necessary but non- value added activity (NNVA). AHP is used to determine the priority of the 7 types of waste. From 7 types of waste, obtained 3 types of waste that has the highest interest rate according to the company for analysis and sought cause of using fishbone diagrams. Once cause of waste is known, then, sought improvement recommendations to reduce or eliminate the waste. VSM and PAM identification results showed that total non value added time in the flow process values are part of Pre Spinning 43.426 minutes. Weighting by AHP obtained 3 types of waste that has the highest interest rate that is waiting, defects, and excessive transportation. Waiting identified among other Drawing Breaker machines is waiting, Carding machines waiting for 0,05 minutes to process 1 Lap and operator of Drawing Breaker waiting for 0.369 minutes to process 16 can Sliver. Defects were identified include defect in the product Lap, Sliver and Roving. Average total amount of defect that occured based on data for November 2012 to November 2013 were 3355.25 kg per month or 5.26% of the average production per month. Excessive transportation identified include transportation from Carding area to Drawing area for 3.14 minutes, from Drawing Breaker to Drawing Finisher for 1,344 minutes, and from Drawing area to Speed area for 19.858 minutes. Transportation is carried back and forth. Recommendations for improvements includes increasing number of Carding machines, increasing capacity of hand truck, addition of temporary operator from maintenance section for transportation process in the Drawing area, eliminating wrapping Lap process, and additional maintenance time. If recommendations for improvements applied, it can minimize production time per month with estimates for 882.42 minutes. That time can be allocated to value added activity, thus increasing amount of production per month.
Other obstract
-
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 670 |
| Uncontrolled Keywords: | Pre Spinning, Waste, Lean Manufacturing, Value Stream Mapping -Pre Spinning, Waste, Lean Manufacturing, Value Stream Mapping |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Hasbi |
| Date Deposited: | 02 Feb 2015 13:48 |
| Last Modified: | 07 Dec 2021 14:09 |
| URI: | http://repository.ub.ac.id/id/eprint/143539 |
Preview |
Text
SKRIPSI.pdf Download (8MB) | Preview |
Actions (login required)
 |
View Item |