Setiyawan, DanangTriagus (2013) Minimasi Waste untuk Perbaikan Proses Produksi Kantong Kemasan Semen dengan Pendekatan Lean Manufacturing (Studi Kasus PT. “XX”). Magister thesis, Universitas Brawijaya.
Abstract
PT. XX bergerak di bidang industri pembuatan kantong kemasan semen. Proses pembuatan kantong kemasan semen di PT. XX secara garis besar dapat dikategorikan menjadi dua tahapan, yaitu: pembuatan tube dan pembuatan bottom. Dari pengamatan awal diketahui bahwa di dalam aliran proses produksinya PT. XX masih sering mengalami hambatan-hambatan. Tingginya prosentase defect sepanjang tahun 2012 yaitu rata-rata sebesar 2,45 % produk cacat setiap bulannya, adanya rework, lead time produksi yang masih panjang, hilangnya waktu produktif karena terjadinya downtime pada mesin merupakan beberapa pemborosan atau waste yang masih terjadi pada perusahaan. Di dalam usaha peningkatan produktivitasnya, perusahaan harus mengetahui kegiatan apa saja yang dapat meningkatkan nilai tambah produk ( value added ), mengurangi berbagai pemborosan ( waste ) dan memperpendek lead time produksinya . Penelitian ini bertujuan mengidentifikasi, menganalisa penyebab waste , dan memberikan rekomendasi perbaikan untuk meminimasi waste . Problem solving yang digunakan dengan melakukan pendekatan konsep lean manufacturing. Identifikasi waste diawali penggambaran current state value stream mapping produksi kemasan semen, dilanjutkan pembobotan waste untuk mengetahui urutan waste yang sering terjadi . Pemilihan detail mapping dengan Value Stream Analysis Tool (VALSAT). Root Cause Analysis dilakukan untuk mencari akar penyebab permasalahan selanjutnya digunakan FMEA untuk mengetahui prioritas improve yang harus dilakukan, dan terakhir tahap penggambaran future state value stream mapping . Hasil pengolahan data diperoleh urutan waste yang paling dominan yaitu defect, waiting, inventory, excessive transportation, overproduction , inappropriate processing , unneccessary motion , environment healthy and safety dan underutilized people . Detail mapping yang digunakan untuk proses analisis adalah Process Activity Mapping, Supply Chain Responce Matrix dan Quality Filter Mapping . Apabila dilakukan usulan perbaikan maka diperoleh waktu untuk operation selama 83 menit, transportation selama 18,2 menit, inspection selama 5 menit, storage selama 13,2 menit dan waktu delay dapat dieliminasi. Terjadi penurunan waktu produksi dari 138,4 menit menjadi 119,4 menit. Prosentase penurunan lead time proses produksi sebesar 13,7 % dari waktu sebelum dilakukannya perbaikan.
English Abstract
Factory XX having activities as production for cement packaging. process for cement packaging production categorized into two major steps : production for tube and production for bottom. From early observation, re are lots of problems at production processes line for cement packaging at factory XX. re problems including high defect at year 2012 with average 2.45% defect product monthly, rework process, and long way of production lead time, and also loosing productive time because machine downtime which leading to time production loss or waste within company. In order to increase productivity, company should manage activities leading towards increasing valued added, decreasing several waste whitin all company lines, and to decreasing production lead time. study was aimed for identification, analyzed waste caused problems, and giving recovery recommendation for minimizing waste. problem solving at study was using lean manufacturing concept approach. waste identification began with identification of production current state value stream mapping, followed with weighting waste in order to understanding root of problem within production process. detail mapping selection was using Value Stream Analysis Tools (VALSAT). Root Cause Analysis was used in order to understanding root of problem for production process followed by FMEA for understanding improving priority which has to be done, and last step was to identify future state value stream mapping. From data analysis result, we found that most dominant waste order is defect, waiting, inventory, excessive transportation, overproduction, inappropriate processing, unnecessary motion, environment health and safety and also underutilized people. mapping detail used for analysis process as Process Activity Mapping Supply Chain Response Matrix and Quality Filter Mapping. With adding recovery process we found operation time is 83 minute, transportation for 18.2 minute, inspection for 5 minute, storage for 13.2 minute and delay time could be eliminated. From result of study we found decreasing of production time from 138.4 minute to 119.4 minute. Decreasing lead time process could reach 13.5% comparing before recovery step.
| Item Type: | Thesis (Magister) |
|---|---|
| Identification Number: | TES/668.419 2/SET/m/041305373 |
| Subjects: | 600 Technology (Applied sciences) > 668 Technology of other organic products > 668.4 Plastics |
| Divisions: | S2/S3 > Magister Teknik Elektro, Fakultas Teknik |
| Depositing User: | Endro Setyobudi |
| Date Deposited: | 08 Apr 2014 16:38 |
| Last Modified: | 08 Apr 2014 16:38 |
| URI: | http://repository.ub.ac.id/id/eprint/160192 |
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