Implementasi Lean Six Sigma untuk Mereduksi Waste pada Proses Produksi Obat X di Industri Manufaktur Farmasi

Widyatmoko, Adiyodha Ayudha (2023) Implementasi Lean Six Sigma untuk Mereduksi Waste pada Proses Produksi Obat X di Industri Manufaktur Farmasi. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT XYZ adalah salah satu perusahaan BUMN yang bergerak di bidang industri farmasi. Salah satu produk utama dengan kuantitas produksi terbanyak yang diproduksi oleh PT XYZ merupakan suatu obat tablet salut generik dengan nama Obat X. Pada proses produksi Obat X, ditemukan bahwa terdapat pemborosan atau waste yang terdeteksi, seperti banyaknya kejadian waiting antar proses, tingginya angka jarak perpindahan material, banyaknya aktivitas yang tidak menambah nilai terhadap produk, serta munculnya defect pada kemasan produk. Oleh karena itu, perlu dilakukan usaha perbaikan pada proses produksi Obat X yang bertujuan untuk mengurangi waste selama proses produksi Obat X. Pada penelitian ini, dilakukan suatu perbaikan berupa usaha mereduksi waste pada proses produksi Obat X di PT XYZ menggunakan pendekatan lean six sigma. Metode lean six sigma merupakan gabungan dari pendekatan lean manufacturing serta pendekatan six sigma. Pendekatan lean manufacturing digunakan dalam mengidentifikasi waste yang ada pada proses produksi, sedangkan pendekatan six sigma berfokus pada pengurangan variasi serta waste pada proses dengan menerapkan framework define, measure, analyze, dan improve, (DMAI). Tahapan awal pada penelitian ini adalah mengidentifikasi eksistensi waste potensial menggunakan beberapa lean tools seperti Value Stream Mapping (VSM) dan Process Activity Mapping (PAM). Kemudian, dilakukan penentuan critical waste menggunakan metode genba shikumi. Dari identifikasi critical waste yang telah diperoleh, selanjutnya dilakukan analisis akar penyebab utama terjadinya critical waste tersebut menggunakan five whys analysis. Pada analisis Failure Modes and Effects Analysis (FMEA), ditentukan nilai severity, occurrence, serta detection pada setiap permasalahan untuk dicari nilai Risk Priority Number (RPN). Nilai RPN dari hasil analisis FMEA kemudian dievaluasi dengan metode fuzzy weighted geometric mean untuk diketahui agregasi penilaian untuk setiap permasalahan serta bobot kepentingan relatif untuk setiap faktor. Hasil evaluasi nilai RPN dengan metode fuzzy adalah nilai fuzzy-RPN yang digunakan untuk menentukan tingkat prioritas saran alternatif perbaikan. Didapatkan bahwa saran alternatif perbaikan untuk permasalahan dengan urutan peringkat fuzzy-RPN tertinggi adalah pembuatan quality form ruahan produk sebelum cetak dan inspection form proses percetakan, pemberian rancangan analisis dan perhitungan utilisasi mesin eksisting, penyesuaian jadwal produksi dengan menerapkan metode penjadwalan Shortest Proccesing Time (SPT), dan perbaikan teknik demand forecasting menggunakan teknik double exponential smoothing.
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PT XYZ is a state-owned company engaged in the pharmaceutical industry. One of the leading products with the highest production quantity produced by PT XYZ is a generic coated tablet drug named Drug X. In the production process of Drug X, it was found that there was detected waste, such as the number of waiting events between processes, the high number of material transfer distances, the many activities that did not add value to the product, and the appearance of defects in product packaging. Therefore, it is necessary to make efforts to improve the production process of Drug X, which aims to reduce waste during the production process of Drug X. In this study, an improvement was made in the form of efforts to reduce waste in the production process of Drug X at PT XYZ using a lean six sigma approach. The lean six sigma method combines the lean manufacturing and six sigma approaches. The lean manufacturing approach is used to identify waste in the production process, while the six sigma approach focuses on reducing variation and waste in the process by applying the define, measure, analyze, improve, and control (DMAIC) framework. The initial stage of this research is to identify the existence of potential waste using several lean tools, such as Value Stream Mapping (VSM) and Process Activity Mapping (PAM). Then, the determination of critical waste is carried out using the genba shikumi method. From the identification of critical waste that has been obtained, then an analysis of the primary root causes of the occurrence of critical waste is carried out using the five whys analysis. In the Failure Modes and Effects Analysis (FMEA) analysis, the severity, occurrence, and detection values for each problem are determined to determine the Risk Priority Number (RPN). The RPN value from the results of the FMEA analysis is then evaluated using the fuzzy weighted geometric mean method to determine the aggregation of ratings for each problem and the relative importance weight for each factor. The results of evaluating the RPN value with the fuzzy method are the fuzzy-RPN values used to determine the priority level of suggestions for alternative improvements. It was found that alternative suggestions for improvement for problems with the highest order of fuzzy-RPN rankings were making bulk product quality forms before printing and printing process inspection forms, providing analysis designs, and calculating existing machine utilization, adjusting production schedules by applying the Shortest Processing Time (SPT) scheduling method, and improving demand forecasting techniques using double exponential smoothing techniques.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean manufacturing, six sigma, lean six sigma, DMAIC, genba shikumi, FMEA, fuzzy.
Subjects:	Q Science > QA Mathematics > QA9.64 Fuzzy logic T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Adiyodha Ayudha Widyatmoko
Date Deposited:	03 Aug 2023 08:02
Last Modified:	03 Aug 2023 08:02
URI:	http://repository.its.ac.id/id/eprint/102289

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