Sari, Etania Desy Anjar (2018) Minimasi Waste dengan Menggunakan Lean Manufacturing Tools pada Proses Produksi Biskuit Cream di PT. Unimos. Sarjana thesis, Universitas Brawijaya.
Abstract
Penerapan lean manufacturing memiliki peranan yang penting bagi suatu perusahaan. Lean manufacturing merupakan metode yang digunakan untuk perampingan proses produksi di perusahaan, salah satunya adalah upaya meminimasi terjadinya waste pada suatu proses produksi. PT. Unimos merupakan perusahaan manufaktur di bidang makanan, khususnya memproduksi biskuit dan wafer. Dalam proses produksinya, terdapat beberapa waste yang terjadi. Waste dapat menyebabkan proses produksi menjadi terhambat, sehingga perlu dilakukan minimasi terhadap waste yang terjadi. Minimasi waste perlu dilakukan untuk meningkatkan efektivitas dan efisiensi pada proses produksi di perusahaan. Tujuan penelitian ini adalah menganalisis waste dan penyebab waste yang terjadi pada proses produksi biskuit cream di PT. Unimos. Hasil penelitian diharapkan dapat memberikan kontribusi bagi perusahaan dalam upaya meminimasi terjadinya waste pada proses produksi di PT. Unimos. Operator di setiap workstation dapat mengetahui kebutuhan-kebutuhan aktual untuk memenuhi target produksi, sehingga proses produksi dapat berjalan secara optimal. Dalam penelitian ini digunakan metode Value Stream Mapping (VSM), Process Acitivity Mapping (PAM), Supply Chain Response Matrix (SCRM), dan Root Cause Analysis (RCA). Tujuan dari Value Stream Mapping adalah untuk mendapatkan gambaran mengenai aliran informasi dan aliran material serta berapa lama waktu Value Added (VA) dan Non Value Added (NVA) pada proses produksi biskuit cream. Process Activity Mapping dan Supply Chain Response Matrix digunakan untuk melakukan detail mapping untuk menentukan waste yang terjadi. Root Cause Analysis untuk mengetahui faktor penyebab terjadinya waste. Data primer penelitian didapatkan berdasarkan hasil observasi pada proses produksi dan wawancara dengan pihak-pihak terkait di perusahaan. Pengambilan waktu siklus menggunakan Stopwatch Time Study (STS) dengan 20 replikasi untuk masing-masing aktivitas. Berdasarkan analisis Value Stream Mapping (VSM), diketahui proses creaming dan packaging belum dapat memenuhi permintaan pelanggan. Masing-masing persentase aktivitas Value Added (VA), Non Value Added (NVA), dan Necessary but Non Value Added (NNVA) dengan menggunakan Process Activity Mapping (PAM) adalah 46,83%, 6,62%, dan 46,55%. Hasil PAM menunjukkan waste waiting dan transportation sebesar 3,61 menit dan 12,73 menit. Berdasarkan Supply Chain Response Matrix (SCRM), total waktu response supply chain dalam sistem adalah 10 hari, dengan nilai days physical stock terbesar terjadi pada proses penyimpanan bahan baku dan proses penyimpanan produk jadi dengan nilai 28,104 jam dan 27,216 jam. Hasil penelitian menunjukkan waste yang terjadi adalah waste overstock tepung BS, waste waiting, waste transportation, dan waste overproduction. Perbaikan yang dilakukan berdasarkan analisa Root Cause Analysis adalah memperbaiki pola aliran pada layout perusahaan dari straight line menjadi serpentine, menambah 1 operator proses creaming, membuat tabel penentuan standar supplier, dan membuat lembar kendali jadwal produksi harian yang detail. Hasil perbaikan menunjukkan terjadinya penurunan lead time sebesar 11,35 menit.
English Abstract
The implementation of lean manufacturing has an important role for a company. Lean manufacturing is a method that improve the production process in the company, such as to minimize the occurrence of waste in the production process. PT. Unimos is a food manufacturing company, especially producing biscuits and wafers. In the production processes, there were some waste that occured. Waste can cause the production process become inhibited, so it needs to be minimized. Minimization of waste needs to be conducted to improve the effectiveness and efficiency in the production processes. The purpose of this study is to analyze the waste and factors that cause waste in the production process at PT. Unimos. The result of this study are expected to contribute in the effort of minimizing the occurance of waste in the production process at PT. Unimos. Operators in each workstation are able to know the actual needs to reach production targets, so that the production process will run optimally. This research used Value Stream Mapping (VSM), Process Activity Mapping (PAM), Supply Chain Response Matrix (SCRM), and Root Cause Analaysis (RCA). The purpose of Value Stream Mapping was to get an overview of the information and material flows, and to know how long the Value Added (VA) and Non Value Added (NVA) time in the production process of cream biskuit. Process Activity Mapping and Supply Chain Response Matrix were used to perform detail mapping to determine the factors causing waste. Primary data of this research were obtained based on observation result in production process and interview with the manager who related in the topic of this research. The cycle time was obtained from the Stopwatch Time Study (STS) method with 20 replicates for each activities. Based on Value Stream Mapping (VSM) analysis, it was known that the creaming and packaging process has not been able to meet customer demand. Each percentage of Value Added (VA), Non Value Added (NVA), and Necessary but Non Value Added (NNVA) activities based on Process Activity Mapping (PAM) were 46.83%, 6.62%, and 46.55 %. PAM results show waste waiting and transportation were 3.61 minutes and 12.73 minutes. Based on the Supply Chain Response Matrix (SCRM), the total supply chain response time in the system was 10 days, with the largest days physical stock value occurring in the process of raw material storage and in the process of finished products storage with the value were 28.104 hours and 27.216 hours. The results showed the waste that occured were waste overstock BS flour, waste waiting, waste transportation, and waste overproduction. Improvements made based on the Root Cause Analysis were by improving flow patterns in the company's layout from straight line to serpentine, by adding 1 operator in creaming process, by creating a standard supplier determination table, and by creating a detailed daily production schedule sheet. Improvement results showed a decrease in lead time by 11.35 minutes.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2018/35/051800686 |
| Uncontrolled Keywords: | Waste, Value Stream Mapping (VSM), Process Activity Mapping (PAM), Supply Chain Response Matrix (SCRM), Root Cause Analysis (RCA). |
| Subjects: | 600 Technology (Applied sciences) > 658 General management > 658.5 Management of production |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Budi Wahyono Wahyono |
| Date Deposited: | 26 Mar 2018 06:47 |
| Last Modified: | 16 Oct 2021 06:35 |
| URI: | http://repository.ub.ac.id/id/eprint/8958 |
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