Arisandi, Kirana Rahmayanti (2019) Upaya Minimasi Lead Time Proses Loading Unloading Produk Semen Bag Menggunakan Value Stream Mapping. Sarjana thesis, Universitas Brawijaya.
Abstract
PT. Semen Indonesia (Persero) Tbk. merupakan perusahaan yang bergerak di industri semen. Permasalahan yang terjadi pada perusahaan yaitu masih banyak truk yang memiliki rata-rata waktu proses melebihi standar yang sudah ditetapkan perusahaan. Terdapat permasalahan waktu tunggu yang lama sehingga diperlukan identifikasi waste di sepanjang aliran proses loading unloading produk semen mulai dari Cargo hingga Timbangan isi serta di Stasiun Babat. Waktu tunggu yang lama menyebabkan lead time proses yang panjang. Identifikasi waste dilakukan dengan Value Stream Mapping (VSM) untuk memetakan aliran proses loading unloading mulai dari Cargo hingga Timbangan Isi serta di Stasiun Babat. Setelah pemetaan, dilakukan analisis lebih lanjut dengan Process Activity Mapping (PAM) untuk mengetahui aktivitas value added, non value added, dan necessary but non value added berdasarkan elemen kerja. Dari hasil PAM, didapatkan waiting time yang tinggi dan dicari akar permasalahannya dengan Root Cause Analysis (RCA). Pengambilan data waktu proses menggunakan Stopwatch Time Study (STS). Terakhir adalah pembuatan Future State Mapping (FSM) berdasarkan usulan perbaikan yang telah diberikan. Dari hasil perhitungan PAM, didapatkan bahwa pada proses loading unloading perusahaan ditemukan adanya waste sepanjang proses bisnis tersebut. Waste terbesar yaitu waste waiting dan waste unnecessary motion. Nilai total waste waiting dan waste unecessary motion sebesar 71,36%. Berdasarkan hasil RCA, akar permasalahan dari waste waiting yaitu adanya set up mesin Rotopacker pemuatan 50kg menjadi 40kg, proses pemuatan di Packer membutuhkan waktu lama, dan sistem borongan yang diterapkan perusahaan di Stasiun Babat. Sedangkan akar permasalahan dari waste unnecessary motion yaitu metode penyerahan SIPS yang masih manual dan posisi petugas SPJ kurang ergonomis. Usulan perbaikan untuk meminimasi waste waiting yaitu dengan melakukan penjadwalan untuk truk yang akan melakukan pemuatan semen dengan melakukan pembagian waktu dalam 1 shift pemuatan semen 40kg dan 50kg, pemuatan semen di Packer dilakukan dengan sistem girder chain hoist atau dengan sistem palletizer, serta melakukan evaluasi kinerja dan membuat sistem borongan baru untuk pihak outsourcing berdasarkan lama waktu terbongkarnya truk. Sedangkan usulan perbaikan untuk waste unnecessary motion yaitu menerapkan sistem digitalisasi Packer atau dengan sistem katrol yang terhubung dari lantai 4 menuju lantai 1 untuk menyerahkan SIPS ke gudang kantong dan memindahkan posisi petugas SPJ dekat dengan kepala truk agar mempermudah supir truk mencetak SPJ. Dari usulan perbaikan yang telah diberikan bahwa terjadi penurunan lead time proses loading unloading dari 569,6 menit menjadi 411,09 menit dengan selisih sebesar 158,51 menit.
English Abstract
PT Semen Indonesia (Persero) Tbk. is a company in the cement-producing industry. Problem arising within the company is that there are still many instances where the trucks processing time are beyond the standard processing time set by the company. The main issue lies in the long waiting time, therefore, waste identification is needed along the loading-unloading process of cement bag product starting from the Cargo to the Filling Scales and finally ends at Babat Station. Long waiting time causes a long lead time as well. Waste identification was done using the Value Stream Mapping (VSM) method to map the loading-unloading process flow starting from the Cargo till the Filling Scales and the Babat Station. After the mapping, further analysis was done using the Process Activity Mapping (PAM) to identify Value Added, Non Value Added, and Necessary but Non Value Added activities based on its work elements. Results of PAM analysis showed the activity with highest waiting time, Root Cause Analysis (RCA) was used to solve the problem at its roots. Data gathering was done using the Stopwatch Time Study (STS) method. Finally, Future State Mapping (FSM) was made based on improvement recommendations. From the PAM analysis result, it was acknowledged that the loading-unloading process of the company contained significant waste. The greatest type of waste was waiting waste and unnecessary motion waste. Total value of waiting waste and unnecessary motion waste was 71,36%. Based on RCA, the root causes of the waiting waste problem were the set up time of Rotopacker machine from 50kg to 40kg, the long packing time with the Packer itself, and the batch system implemented by the company at Babat Station. While the root causes of the unnecessary motion problem were the SIPS manual handover method and the less ergonomic positioning of SPJ officer. Improvement recommendations to solve the waiting waste problem were to schedule the trucks so that 40kg and 50kg were done at a time, cement bag packing at the Packer were to be done using the Girder Chain Hoist system or the Palletizer system, and to evaluate the performance and make new batch system for outsourced third-parties based on the time it takes to process the trucks. Improvement recommendations to solve the unnecessary motion waste were to implement digitalized Packer system or to use pulley system between the 4th and 1st floor to handover the SIPS to the warehouse, and to position the SPJ officers close to trucks’ front-end so as to ease the printing of SPJ for truck drivers. From the given recommendations, lead time of loading-unloading process could be reduced from 569,6 minutes to 411,09 minutes with a difference of 158,51 minutes.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2019/227/051904886 |
| Uncontrolled Keywords: | Waste Waiting, Waste Unnecessary Motion, Value Stream Mapping, Process Activity Mapping, Root Cause Analysis., |
| Subjects: | 600 Technology (Applied sciences) > 658 General management > 658.3 Personnel management (human resource management) > 658.31 Elements of personnel management > 658.312 Conditions of employment, performance rating, utilization of personnel > 658.312 5 Performance rating (evaluation) |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Budi Wahyono Wahyono |
| Date Deposited: | 13 Nov 2020 04:25 |
| Last Modified: | 02 Aug 2023 01:13 |
| URI: | http://repository.ub.ac.id/id/eprint/171733 |
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