Satriyo, Dimas Budi and Dr. Eng. Zefry Darmawan,, ST., MT. (2023) Implementasi Lean Manufacturing untuk Mereduksi Waste Menggunakan Value Stream Mapping pada Proses Produksi Gendongan Bayi. Sarjana thesis, Universitas Brawijaya.
Abstract
Angka pertumbuhan penduduk yang cukup tinggi berdampak pada terbukanya peluang bisnis kelengkapan bayi dan anak. Peluang tersebut dimanfaatkan oleh sebuah produsen gendongan bayi dari Kota Malang, yaitu PT Safa Swarna Cipta. Pemanfaatan peluang tersebut berdampak pada dikenalnya brand perusahaan, sehingga didapatkan tingkat order yang tinggi. Namun, saat ini perusahaan masih kesulitan dalam produksi pemenuhan order pelanggan karena kurangnya produktivitas produksi dan tingginya lead time produksi. Untuk tetap dapat bersaing dan memenangkan pasar, perusahaan harus memenuhi seluruh order dengan kualitas produk yang tinggi pula. Dalam mencapai hal tersebut, perusahaan harus meningkatkan efisiensi dan efektivitas produksi sehingga produktivitas produksi meningkat dengan cara mengeliminasi waste pada proses produksi gendongan bayi. Eliminasi waste dapat dicapai melalui implementasi lean manufacturing. Pada penelitian ini, melalui observasi awal ditemukan waste dalam proses produksi gendongan bayi yang dapat mengganggu produktivitas perusahaan. Untuk mereduksi waste yang ditemukan, maka diperlukan pengamatan lebih lanjut dengan menggunakan tools lean manufacturing. Langkah yang dilakukan adalah dengan memetakan proses produksi dengan menggunakan value stream mapping (VSM); dilanjutkan dengan penyusunan process activity mapping (PAM) untuk mengelompokkan aktivitas produksi ke dalam kelompok aktivitas value added, non-value added, dan necessary non-value added; kemudian dilakukan pembobotan waste dengan menggunakan waste assessment model (WAM), dan berdasarkan pembobotan waste dilakukan analisis akar penyebab waste kritis dengan menggunakan cause and effect diagram. Berdasarkan pemetaan current state mapping, didapatkan lead time proses produksi sebesar 1480 menit 32 detik dengan value added ratio sebesar 27,40%, sehingga dapat diartikan proses produksi gendongan bayi belum lean. Selanjutnya dilakukan pembobotan waste menggunakan WAM dan didapatkan 4 waste kritis berupa waste inventory, waiting, transportation, dan motion. Kemudian dilakukan analisis akar penyebab waste dengan menggunakan cause effect diagram. Hasil analisis akar penyebab waste digunakan sebagai dasar penentuan rekomendasi perbaikan. Rekomendasi perbaikan yang diberikan antara lain: penambahan operator, penerapan material requirement planning, perancangan inventory, perancangan sistem material handling, perbaikan layout, penggabungan proses, perbaikan sistem pengiriman barang, penerapan sistem produksi batch kecil, penerapan preventive maintenance, penyusunan SOP inventory, dan penerapan 5S. Setelah mendapatkan rekomendasi perbaikan dilakukan pemetaan menggunakan future state mapping untuk mendapatkan gambaran kondisi perusahaan setelah dilakukan implementasi rekomendasi perbaikan. Didapatkan perbaikan berupa penurunan lead time sebesar 911 menit 27 detik, dan peningkatan value added ratio menjadi 69,54%.
English Abstract
The relatively high population growth rate has led to the emergence of opportunities in the baby and child accessory business. These opportunities have been capitalized upon by a baby carrier manufacturer from Malang City, namely PT Safa Swarna Cipta. The utilization of these opportunities has resulted in the recognition of the company's brand, leading to a high level of orders. However, the company currently faces challenges in fulfilling customer orders due to low production productivity and extended production lead times. In order to remain competitive and dominate the market, the company must meet all orders with highquality products. To achieve this, the company needs to enhance production efficiency and effectiveness, thereby increasing overall production productivity by eliminating waste in the baby carrier production process. Waste elimination can be achieved through the implementation of lean manufacturing. This study initially identified waste in the baby carrier production process that could potentially hinder overall productivity. To address this waste, a deeper examination was conducted using lean manufacturing tools. The process begins by mapping the production process through value stream mapping (VSM), followed by process activity mapping (PAM) to categorize production activities into value-added, non-value added, and necessary nonvalue added groups; then the waste is weighted using the waste assessment model (WAM), and based on the waste weighting, a root cause analysis of critical waste is carried out using a cause and effect diagram. Based on the mapping through current state mapping, the lead time for the production process is 1480 minutes 46 seconds with a value added ratio of 27,40%, which means that the baby carrier production process is not lean. Waste weighting using WAM, obtained 4 critical wastes in the form of waste inventory, waiting, transportation, and motion. A root cause analysis using cause effect diagram are conducted to delve into the root cause of the wastes. The results of root cause analysis of waste are used as a basis for determining improvement recommendations. Improvements recommendations include: adding operators, implementing material requirement planning, designing inventory, designing material handling systems, improving factory layout, merging processes, improving goods delivery systems, implementing small batch production systems, implementing preventive maintenance, preparing inventory SOPs, and implementing 5S. Following the improvement recommendations, future state mapping was carried out to get an overview of the company's condition after implementing the improvement recommendations. The Improvements indicating a decreased lead time by 911 minutes 27 seconds, and increased value added ratio to 69,54%.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 052307 |
| Uncontrolled Keywords: | Lean Manufacturing, Value Stream Mapping (VSM), Process Activity Mapping (PAM), Waste Assessment Model (WAM), Cause and Effect Diagram (CED) |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Unnamed user with username suprihatin |
| Date Deposited: | 11 Jan 2024 02:32 |
| Last Modified: | 11 Jan 2024 02:32 |
| URI: | http://repository.ub.ac.id/id/eprint/207900 |
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