Nursiadi, Mizan (2025) Analisis Lean Six Sigma Untuk Mengurangi Waste Dalam Proses Peleburan Timah: Studi Pada Teknologi Tanur Reverberatory Dan TSL Ausmelt. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT Timah Tbk, produsen timah global, menghadapi inefisiensi operasional berupa tingginya stok Work in Progress (WIP). Menghadapi tantangan tersebut, PT Timah Tbk telah beralih dari teknologi utama Reverberatory Furnace ke Top Submerged Lance (TSL) Ausmelt. Namun, meski telah beralih, stok WIP pada Terak Granular Ausmelt dan Timah Besi justru masih meningkat, masing-masing sebesar 1,285% dan 22%, yang berpotensi menghambat pendapatan perusahaan. Penelitian ini bertujuan mengevaluasi keputusan perubahan teknologi,
mengidentifikasi pemborosan WIP, dan meningkatkan efisiensi proses dengan Lean Six Sigma berbasis DMAIC. Pada fase Define dilakukan pemetaan proses menggunakan SIPOC, PAM, dan Current VSM. Fase Measure melibatkan pengukuran lean metrics dan pareto diagram untuk mengidentifikasi waste kritis.
Analisis akar penyebab dilakukan dengan RCA dan FMEA. Fase Improve mencakup perancangan future VSM serta kajian kelayakan teknis dan ekonomi, sedangkan fase Control merancang SOP untuk perbaikan.
Hasil menunjukkan Teknologi TSL Ausmelt lebih efisien, mengurangi waktu proses 41,75% dan meningkatkan produksi logam harian 94,46%. Rekomendasi mencakup revisi prosedur reduksi Sn untuk menghemat Rp 21,9 juta per ton Sn Input dan investasi crusher pada Timah Besi untuk efisiensi Rp 338 juta per tahun dan proyeksi pendapatan Rp 299 juta per kampanye lebur. Penelitian ini menjadi panduan praktis untuk mengelola transisi teknologi dan efisiensi operasional.
Kata Kunci: Lean Six Sigma, Peleburan Timah, Reverberatory, TSL Ausmelt, Work in Progress (WIP)
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PT Timah Tbk, a global tin producer, faces operational inefficiencies due to high Work in Progress (WIP) inventory levels. To address this challenge, PT Timah Tbk transitioned its core smelting technology from Reverberatory Furnace to Top Submerged Lance (TSL) Ausmelt. However, despite the transition, WIP levels for Ausmelt Granular Slag and Tin Iron have continued to rise by 1,285% and 22%, respectively, potentially hindering the company’s revenue realization.
This study aims to evaluate the technological shift, identify WIP waste, and enhance process efficiency using Lean Six Sigma with the DMAIC framework. The Define phase includes process mapping with SIPOC, PAM, and Current VSM. The Measure phase utilizes lean metrics and pareto diagrams to identify critical waste. Root cause analysis is conducted using RCA and FMEA in the Analyze phase. The Improve phase involves designing a future VSM and conducting technical and economic feasibility studies, while the Control phase develops SOPs for implementing improvements.
The results show that TSL Ausmelt technology is more efficient, reducing processing time by 41.75% and increasing daily metal production by 94.46%. Recommendations include revising the Sn reduction procedure to save Rp 21.9
million per ton of Sn input and investing in a crusher for Tin Iron to achieve annual efficiency savings of Rp 338 million and projected revenue of Rp 299 million per
smelting campaign. This study serves as a practical guide for managing technological transitions and improving operational efficiency.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Lean Six Sigma, Peleburan Timah, Reverberatory, TSL Ausmelt, Work in Progress (WIP), Tin Smelting |
| Subjects: | T Technology > T Technology (General) T Technology > T Technology (General) > T56.8 Project Management T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures > TS155 Production control. Production planning. Production management T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Mizan Nursiadi |
| Date Deposited: | 02 Feb 2025 06:18 |
| Last Modified: | 02 Feb 2025 06:18 |
| URI: | http://repository.its.ac.id/id/eprint/117591 |
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