Implementation of Lean Six Sigma in Minimizing Wastes in The Packaging Process of Monosodium Glutamate (MSG) at PT. Ajinomoto Indonesia

Azzarani, Sofia (2023) Implementation of Lean Six Sigma in Minimizing Wastes in The Packaging Process of Monosodium Glutamate (MSG) at PT. Ajinomoto Indonesia. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Ajinomoto Indonesia is a food and beverage company that produces cooking spices. This research was conducted at PT Ajinomoto Indonesia in Mojokerto and aimed to identify the possibility of waste appearing in the packaging process and provide alternative improvements to improve the packaging process by analyzing the causes of critical waste. This research focuses on the waste of the packaging process of MSG, the main product with the highest production by PT Ajinomoto Indonesia. Waste that occurs in the packaging process is in the form of overproduction and inventory due to the make-to-stock strategy, motion waste in the form of inefficiencies in product transfer to the three production zones and unnecessary movements of operators, waiting for waste in the form of breakdown machines and waiting time for special task operators, and defects in the form of rejected products and products that can still be reworked where the bag type obtained 15,985,090 kg or 0.226% of the rejected product of MSG for the bag type. Primary data obtained from direct interviews with related parties and secondary data obtained from August 2022 to December 2022 include product defects, product targets and achievements, machine breakdown frequency, and packaging process flow. This research used the Lean Six Sigma method DMAIC without carrying out the control stage. The inspection carried out by PT Ajinomoto Indonesia is by using an automatic machine and visual checking by the quality control team. The use of lean six sigma helps provide output and improvements related to eliminating waste in this research. In the define phase, the critical waste is integrated from the seven wastes of lean by using the process activity mapping method. At the measure phase, DPMO and sigma values are calculated to determine the existing condition of the company, and Waste Assessment Model also will be carried out to determine the critical waste. The critical waste that has been found in the define and measure phase is then analyzed in the Analyze phase by using Root Cause Analysis and Failure Mode and Effect Analysis to find out the cause of the critical waste. After obtaining the causes of critical waste, the improvement phase will be conducted by providing recommendations for improvement to the company

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Six Sigma, DMAIC, DPMO, Critical Waste, Process Activity Mapping, FMEA, Waste Assessment Model, Root Cause Analysis
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. T Technology > TS Manufactures > TS195 Packaging
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Sofia Azzarani
Date Deposited:	01 Aug 2023 03:13
Last Modified:	01 Aug 2023 03:13
URI:	http://repository.its.ac.id/id/eprint/100800

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