Analisis Reduksi Waste Pada Industri Pelumas Dengan Metode Seven Value Stream Mapping Tools

Priyatna, Alim Adi (2025) Analisis Reduksi Waste Pada Industri Pelumas Dengan Metode Seven Value Stream Mapping Tools. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Production Unit Jakarta adalah salah satu unit produksi pelumas yang dimiliki PT Pertamina Lubricants. Proses produksi minyak lumas tidak terlepas dari beberapa kendala di antaranya adalah tingginya idle time produksi saat proses pengisian minyak lumas ke dalam kemasan. Dampak dari idle time ini yaitu munculnya biaya-biaya tambahan seperti man power dan utility. Selain itu kendala lainnya adalah defect material dan isu inventory. Rata-rata waktu idle time filling lithos selama rentang waktu Jan-Sept 2024 adalah 14 Hari Kerja atau 1-2 hari perbulan untuk masing-masing line dengan reject rate sebesar 0,17%. Tujuan dari penelitian ini yaitu melakukan analisis terhadap proses produksi yang berdampak terhadap timbulnya waste/pemborosan . Penelitian ini menggunakan Metode Value Stream Mapping (VSM) yang ditunjang dengan Value Stream Mapping Analysis Tools (VALSAT) dan telah dimanfaatkan sebagai salah satu alternatif solusi untuk memecahkan permasalahan yang berkaitan dengan waste/pemborosan. Dan tools yang digunakan yaitu Process Activity Mapping, Supply Chain Response Matrix dan Quality Filter Mapping. Hasil penelitian menunjukkan penurunan idle time produksi sebesar 13%, penurunan reject rate sebesar 0,04%, reduksi waktu tunggu sampling sebesar 61% berkat implementasi lab satelit, pemangkasan cycle time proses sebesar 1,83 detik, dan peningkatan output harian sebesar 30,17%. Meskipun demikian, penelitian ini juga mengidentifikasi anomali peningkatan defect pada jenis defect Karton Sobek Erector yang memerlukan investigasi lebih lanjut. Implikasi manajerial dari penelitian ini menekankan dampak terhadap keberhasilan inisiatif perbaikan dalam meningkatkan dan mempertahankan efisiensi dan kapasitas produksi secara keseluruhan baik dari sisi mempertahankan kompetensi pekerja, performa mesin dan juga biaya-biaya yang timbul dari hasil perbaikan.
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Production Unit Jakarta is one of the lubricant production units owned by PT Pertamina Lubricants. The lubricant oil production process faces several challenges, one of which is the high production downtime during the filling process into packaging. This downtime results in additional costs such as manpower and utilities. Other issues include material defects and inventory problems. The average downtime for Lithos filling lines during the period of January to September 2024 was 14 working days, or about 1–2 days per month for each line, with a reject rate of 0.17%. The objective of this study is to analyze the production process to identify sources of waste or inefficiency. The research utilizes the Value Stream Mapping (VSM) method, supported by Value Stream Mapping Analysis Tools (VALSAT), which have been used as alternative solutions for addressing waste-related issues. The tools employed include Process Activity Mapping, Supply Chain Response Matrix, and Quality Filter Mapping. The results of the study show a 13% reduction in production downtime, a 0.04% decrease in reject rate, a 61% reduction in sampling waiting time thanks to the implementation of a satellite lab, a cycle time reduction of 1.83 seconds, and a 30.17% increase in daily output. Nevertheless, the study also identified an anomaly in the form of an increase in a specific defect type—Torn Carton at the Erector station—which requires further investigation. The managerial implications of this study highlight the success of improvement initiatives in enhancing overall production efficiency and capacity, but also stress the need for deeper analysis of specific emerging issues.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Lubricants, VSM, VALSAT, downtime
Subjects:	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:	Alim Adi Priyatna
Date Deposited:	07 Jul 2025 04:47
Last Modified:	07 Jul 2025 04:47
URI:	http://repository.its.ac.id/id/eprint/119395

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