Implementasi Lean Manufacturing Menggunakan Value Stream Mapping (Studi Kasus: Perusahaan Manufaktur Komponen Otomotif)

Gibran, Daffa Abyan (2023) Implementasi Lean Manufacturing Menggunakan Value Stream Mapping (Studi Kasus: Perusahaan Manufaktur Komponen Otomotif). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Rantai pasok pada Industri Otomotif terdiri dari supplier tier 2 sebagai industri pendukung sekunder, supplier tier 1 sebagai Original Equipment Manufacturer (OEM), manufaktur perakit otomotif sebagai produsen produk otomotif, dan customer. PT XYZ merupakan perusahaan manufaktur komponen otomotif yang mengambil peran sebagai supplier tier 1. Eratnya persaingan global terhadap produk otomotif membuat produsen otomotif memberikan tekanan kepada suppliernya agar dapat memenuhi permintaan komponen otomotifnya. Berlaku pula kepada PT XYZ yang terkena dampak tekanan dari manufaktur perakit otomotif. Namun, permasalahan muncul saat PT XYZ mengalami masalah pemborosan yang menyebabkan seringnya ketidakcapaian target produksi. Hal ini menyebabkan PT XYZ rutin melakukan overtime yang mengakibatkan biaya produksi meningkat. Sehingga PT XYZ memerlukan suatu metode untuk dapat mengidentifikasi waste dan mereduksi lead time produksi untuk dapat mengurangi waktu overtime dan memenuhi permintaan pelanggan tepat waktu. Metode tersebut adalah Lean Manufacturing yang berfokus pada eliminasi pemborosan dan melakukan continous improvement. Dalam implementasinya, metode value stream mapping (VSM) adalah metode paling cocok karena dapat memetakan keseluruhan proses dan dapat meninjau interaksi antar proses. Dengan bantuan metode process acitivity mapping, kondisi current state map dapat diidentifikasi aktivitas yang menimbulkan waste-nya. Waste ini kemudian diidentifikasi akar permasalahannya menggunakan metode 5 whys analysis dan root cause analysis. Hasil analisis tersebut kemudian menjadi landasan untuk dilakukan perbaikan dan mengimplementasikannya ke dalam Future State map. Dalam proses perbaikannya, kondisi masa depan dapat mereduksi lead time produksi dari 5,05 hari menjadi 4,66 hari. Nilai reduksi tersebut diharapkan bisa menyelesaikan permasalahan target produksi yang tidak tercapai sehingga tidak dilakukan overtime.
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The supply chain in the automotive industry consists of tier 2 suppliers as secondary industry supporters, tier 1 suppliers as Original Equipment Manufacturers (OEM), automotive assembler manufacturers as automotive product manufacturers, and customers. PT XYZ is an automotive component manufacturer that takes on the role of a tier 1 supplier. Intense global competition for automotive products has forced automotive manufacturers to put pressure on their suppliers to be able to meet demand for their automotive components. also entitled to PT XYZ which was affected by pressure from the manufacture of automotive assemblies. However, problems arose when PT XYZ experienced waste problems which often led to production targets not being achieved. This causes PT XYZ to routinely perform overtime which results in increased production costs. So that PT XYZ needs a method to be able to identify waste and reduce production lead time in order to reduce overtime and meet customer demands on time. The method is Lean Manufacturing which focuses on eliminating waste and carrying out continuous improvement. In its implementation, the value stream mapping (VSM) method is the most suitable method because it can upset the entire process and can review the interactions between processes. With the help of the Process Activity Mapping method, the condition of the current state map can identify activities that cause waste. This waste is then identified as the root cause using the 5 whys analysis method and root cause analysis. The results of the analysis then become the basis for making improvements and implementing them into the Future State map. In the repair process, future conditions can reduce production lead time from 5.05 days to 4.66 days. The reduction value is expected to solve the problem of production targets that are not achieved so that overtime is not carried out.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Manufacturing, Pemetaan Aliran Nilai, Pemetaan Aktivitas Proses, Value Stream Mapping, Process Activity Mapping
Subjects:	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:	Daffa Abyan Gibran
Date Deposited:	07 Sep 2023 03:15
Last Modified:	07 Sep 2023 03:15
URI:	http://repository.its.ac.id/id/eprint/103616

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