Peningkatan Produktivitas Proses Produksi Batu Bata Tahan Api Di PT. Benteng Api Technic Berbasis Lean Manufacturing

Yuviananda, Lukita (2022) Peningkatan Produktivitas Proses Produksi Batu Bata Tahan Api Di PT. Benteng Api Technic Berbasis Lean Manufacturing. Other thesis, Institut Teknologi Sepuluh Nopember.

Text 02411840000064-Undergraduate_Thesis.pdf - Accepted Version Restricted to Repository staff only until 1 October 2024. Download (2MB) | Request a copy

Abstract

Bangunan konstruksi pada kawasan perkotaan seperti mall, perkantoran, perumahan dan lain sebagainya memiliki potensi terjadinya kebakaran. Kebakaran ini dapat terjadi diakibatkan material konstruksi yang digunakan berasal dari material yang mudah terbakar. Oleh karena itu dibutuhkan komponen bahan bangunan tahan api untuk mereduksi terjadinya kegagalan bangunan saat terjadi kebakaran, diantaranya bata tahan api. PT. Benteng Api Technic merupakan perusahaan yang bergerak dalam bidang manufaktur yang memproduksi Bata Tahan Api (Fire Brick). Di perusahaan ini, lead time proses produksi/ batch cukup panjang karena masih adanya non value added activity. Aktivitas yang tidak memberikan nilai tambah tersebut mengakibatkan waste padaproses produksi, seperti waste waiting pada proses mixing, defect after pressing, defect after firing dan excess processing berupa rework. Penelitian ini bertujuan untuk menghilangkan non value added activity dan waste pada proses pembuatan bata tahan api, guna meningkatkan produktivitas produksi. Lean Manufacturing digunakan untuk mengidentifikasi aktivitas yang tidak bernilai tambah serta mereduksi waste pada setiap proses produksi. Pengamatan terhadap proses dilakukan dalam waktu 3 bulan, disertai interview kepada manager produksi, QA/QC dan petugas lapangan. Non Value Added activity dan waste yang terjadi pada setiap proses kemudian dicari sumber penyebabnya menggunakan Fault Tree Analysis (FTA), selanjutnya dicari solusi untuk mereduksi waste yang terjadi agar efisiensi dan produktivitas proses dapat meningkat. Hasil penelitian menunjukkan bahwa sekitar 6% aktivitas teridentifikasi merupakan Non value added activity (NVA) dan 54% aktivitas merupakan Necessary Non Value Added Activity (NNVA) pada proses inspeksi bahan (mal malan), mixing, pressing dan firing. Waste yang terjadi berupa, waiting, defect, dan rework. Akar penyebab permasalahan tersebut berasal dari peralatan, material maupun pekerja. Untuk mereduksi permasalahan waste waiting pada proses mal-malan, perbaikan yang diusulkan adalah audit SOP dan Work Instruction. Untuk mengatasi permasalahan waiting pada proses mixing (menunggu mesin pressing), dilakukan penambahan 1 mesin pressing dan 3 orang pekerja. Untuk menyelesaikan permasalahan waste defect dan rework after pressing, dilakukan audit SOP dan Work Instruction untuk pengoperasian dan perawatan mesin pressing serta penjadwalan perawatan mesin. Untuk mengatasi permasalahan waste defect and rework after firing dilakukan pembuatan system informasi monitoring proses serta melakukan pelatihan pekerja. Setelah dilakukan perbaikan (improvement), terdapat perubahan Lead time dari 3.06 hari menjadi 2,75 hari/ batch produksi. Efisiensi lead time ini memberikan tambahan produksi bata tahan api sebesar 50.484 bh/ tahun (peningkatan 11%) dan potensi pendapatan sebesar Rp 656.292.000,-/ tahun. Selain itu, reduksi waste waiting dan defect dari proses eksisting dapat memberikan penghematan biaya produksi sebesar Rp. 352.808.160,-/tahun dibandingkan biaya proses produksi eksisting.
=================================================================================================================================
Construction buildings in urban areas such as malls, offices, housing, and so on have the potential for fire to occur. This fire can occur due to the construction materials used being flammable materials. Therefore, fire-resistant building material components are needed to reduce the occurrence of building failures when a fire occurs, including refractory bricks. PT. Benteng Api Technic is a company engaged in manufacturing that produces Fire Brick. In this company, the lead time for the production/batch process is quite long because there are still non-value-added activities. Activities that do not provide added value result in waste in the production process, such as waste waiting in the mixing process, defects after pressing, defects after firing, and excess processing in the form of rework. This study aims to eliminate nonvalue added activity and waste in the process of making refractory bricks, to increase production productivity. Lean Manufacturing identifies activities that do not add value and reduce waste in each production process. Observations of the process were carried out within 3 months, accompanied by interviews with the production manager, QA/QC, and field officers. Non Value Added activities and waste that occur in each process are then searched for the source of the cause using Fault Tree Analysis (FTA), then a solution is sought to reduce the waste that occurs so that the efficiency and productivity of the process can be increased. The results showed that about 6% of the identified activities were non-value added activities (NVA) and 54% of the activities were Necessary Non-Value Added activities (NNVA) in the material inspection process (mal-Malan), mixing, pressing, and firing. Waste that occurs in the form of waiting, defects, and reworks. The root cause of these problems comes from equipment, materials, and workers. To reduce the problem of waste waiting in the mal-malan process, the proposed improvements are audit of SOPs and Work Instructions. To overcome the waiting problem in the mixing process (waiting for the pressing machine), an additional 1 pressing machine and 3 workers were added. To solve the problem of the waste defect and rework after pressing, audits of SOPs and Work Instructions for the operation and maintenance of pressing machines, and scheduling maintenance of pressing machines. To overcome the problem of the waste defect and rework after firing, create a process monitoring information system and training for workers are carried out. After improvement, there is a change in Lead time from 3.06 days to 2.75 days/production batch. This lead time efficiency provides additional production of fire bricks of 50,484 by/year (an 11% increase) and a potential income of Rp. 656,292,000,-/year. In addition, the reduction of waste waiting and defects from the existing process can provide production cost savings of Rp. 352.808.160,-/year compared to the cost of the existing production process.

Item Type:	Thesis (Other)
Additional Information:	RSI 658.5 Yuv p-1 2022
Uncontrolled Keywords:	Lean Manufacturing, Refractory Brick, Non-Value Added Activity, Waste, Fault Tree Analysis
Subjects:	T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Anis Wulandari
Date Deposited:	03 Jul 2024 04:41
Last Modified:	03 Jul 2024 04:41
URI:	http://repository.its.ac.id/id/eprint/108110

Actions (login required)

View Item