Salsabila, Nadhifa Ayu and STP., MP., IPU, Dr. Sucipto and ST. MT., Danang Triagus Setiyawan (2022) Penerapan Metode Lean Six Sigma Dalam Mengurangi Pemborosan Proses Produksi Cokelat Batang (Studi Kasus Kelompok Tani Mulyo Jati, Desa BMJ, Mojokerto, Jawa Timur). Sarjana thesis, Universitas Brawijaya.
Abstract
Indonesia penghasil kakao ke-3 terbesar di dunia setelah Pantai Gading dan Ghana. Olahan kakao yang digemari konsumen ialah cokelat. Salah satu usaha yang mengolah kakao menjadi cokelat bar ialah Kelompok Tani Mulyo Jati. Saat ini kegiatan proses produksi memiliki kendala penyebab pemborosan seperti pengerjaan kembali, tumpukan work in process, waktu tunggu, dan produk cacat. Salah satu cara dalam menyelesaikan masalah dengan meminimasi pemborosan sehingga mampu meningkatkan efektivitas proses produksi. Penelitian ini bertujuan untuk mengidentifikasi pemborosan, menganalisis penyebab pemborosan, dan memberikan usulan perbaikan pada proses produksi. Penelitian menggunakan metode Lean Six Sigma merupakan pendekatan untuk meminimasi pemborosan serta mengontrol aktivitas proses produksi. Tahapan dalam penelitian ini meliputi define, measure, analyze, improve. Define dilakukan perhitungan waktu standar, pembuatan Current State Mapping, dan identifikasi pemborosan. Measure dilakukan pembuatan peta kendali p dan menghitung sigma level. Analyze mencari penyebab pemborosan menggunakan fishbone diagram dan FMEA untuk mengetahui prioritas penyebabnya. Improve merekomendasikan usulan perbaikan dan membuat Future State Mapping. Bedasar hasil penelitian, selama proses produksi terdapat 3 pemborosan yaitu inventory pada stasiun pemecah biji, roasting, dan pemasta. Defect pada stasiun pemecahan biji dan pencetakan. Waiting pada stasiun pemecahan biji, pemasta, dan pengemasan. Penyebab pemborosan yang memiliki prioritas untuk diperbaiki yaitu bahan baku tidak seluruhnya diproses langsung, jam kerja mesin terbatas, ada reheating, banyak bahan baku, serta biji besar dan kecil masih tercampur pada stasiun pemecahan biji. Berdasarkan current state mapping persentase VA sebesar 50,4%; NNVA 3,6%; dan NVA 46% dalam produksi cokelat. Perbaikan dengan future state mapping menghasilkan persentase VA menjadi 92,25%; NNVA 6,86%; dan NVA 0,89%. Dalam penelitian ini minimasi waktu produksi dilakukan sebesar 47,33% Berdasar future state mapping, usulan perbaikan berupa minimasi waktu pada aktivitas mengambil biji dan nibs berserakan, pemecahan biji kembali, proses roasting, reheating, pendinginan, dan menunggu cokelat dikemas. Usulan memanfaatkan tenaga kerja dalam membantu stasiun pengemasan membungkus cokelat, berkontribusi paling besar yaitu 45,57% pada minimasi waktu. Selain itu usaha ini perlu melakukan pengawasan pada stasiun sortasi, mengatur ulang waktu reheating dan roasting, serta menjual sebagain bahan baku dan work in process untuk memperbaiki penyebab pemborosan berdasarkan prioritas tertinggi. Saran untuk peneliti berikutnya, perlu membuat tahap control untuk mengevaluasi usulan perbaikan.
English Abstract
Indonesia is the 3rd largest cocoa producer in the world after Ivory Coast and Ghana. Processed cocoa that is popular with consumers is chocolate bar. One of the businesses that processes cocoa into chocolate bars is the Mulyo Jati Farmer Group. Currently, production process activities have constraints that cause waste such as rework, piles of work in process, waiting time, and defective products. One way to solve the problem is by minimizing waste so as to increase the effectiveness of the production process. This study aims to identify waste, analyze the causes of waste, and provide suggestions for improvements to the production process. Research using the Lean Six Sigma method is an approach to minimize waste and control production process activities. The stages in this research include define, measure, analyze, improve. Define is done by calculating standard time, making Current State Mapping, and identifying waste. The measure is made by making a p control chart and calculating the sigma level. Analyze looking for the causes of waste using fishbone diagrams and FMEA to determine the priority causes. Improve recommends improvement proposals and makes Future State Mapping. Based on the research results, during the production process there are 3 wastes, namely inventory at the cracking, roasting, and pasting stations. Defects in seed crushing and printing stations. Waiting at seed crushing, pasting, and packing stations. Causes of waste that have priority for improvement are raw materials not all processed directly, limited machine working hours, reheating, lots of raw materials, and large and small beans are still mixed at the seed breaking station. Based on current state mapping, the percentage of VA is 50.4%; NNVA 3.6%; and 46% NVA in chocolate production. Improvements with future state mapping resulted in a VA percentage of 92.25%; NNVA 6.86%; and NVA 0.89%. In this study, the minimum production time was carried out by 47.33%. Based on the future state mapping, the proposed improvements are in the form of minimizing time in the activities of picking up seeds and scattered nibs, splitting the beans again, roasting, reheating, cooling, and waiting for the chocolate to be packaged. The proposal to use manpower to help packaging stations wrap chocolate, contributed the most, namely 45.57% to minimizing time. In addition, this business needs to supervise the sorting station, rearrange the reheating and roasting times, as well as sell some of the raw materials and work in process to correct the causes of waste based on the highest priority. Suggestions for future researchers, it is necessary to make a control stage to evaluate proposed improvements.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0522100495 |
| Uncontrolled Keywords: | Cokelat, Proses Produksi, Minimasi Pemborosan, Lean Six Sigma, Current State Mapping, FMEA, Future State Mapping, Chocolate, Process Production, Minimization of Waste, Lean Six Sigma, Current State Mapping, FMEA, Future State Mapping |
| Subjects: | 300 Social sciences > 338 Production > 338.1 Agriculture > 338.16 Production efficiency |
| Divisions: | Fakultas Teknologi Pertanian > Teknologi Industri Pertanian |
| Depositing User: | soegeng sugeng |
| Date Deposited: | 19 May 2023 02:51 |
| Last Modified: | 19 May 2023 02:51 |
| URI: | http://repository.ub.ac.id/id/eprint/199886 |
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