Aplikasi Penerapan Lean Manufacturing Untuk Meningkatkan Efisiensi Produksi Cell Capsule Pada Perusahaan Manufaktur Filter Rokok

Refandy, Efan Aditya Raya (2025) Aplikasi Penerapan Lean Manufacturing Untuk Meningkatkan Efisiensi Produksi Cell Capsule Pada Perusahaan Manufaktur Filter Rokok. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Perusahaan Manufaktur Filter Rokok di Indonesia menghadapi tantangan dalam menjaga efisiensi produksi akibat tingginya Work In Process (WIP) yang berdampak pada waktu tunggu dan lead time. Penelitian ini bertujuan mengidentifikasi dan mengurangi pemborosan (waste) dalam produksi cell capsule menggunakan pendekatan Lean Manufacturing. Metode yang digunakan meliputi Value Stream Mapping untuk pemetaan aliran produksi, Process Activity Mapping untuk klasifikasi aktivitas, From-To Chart untuk analisis perpindahan material, Genba Shikumi untuk identifikasi waste kritis serta 5 Why’s untuk menemukan akar penyebab masalah. Hasil penelitian menunjukkan 96,38% lead time merupakan waktu menunggu pengiriman ke customer. Proses produksi didominasi aktivitas necessary but non value added, terdapat ketidakseimbangan waktu antar proses, dan indikasi waste transportation pada material handling. Rekomendasi perbaikan difokuskan pada menurunkan standar waktu kebijakan buffer date, menurunkan waktu change order dengan penerapan metode SMED, penyesuaian standar counterslice dengan kualitas sparepart, pengaturan tekanan angin kompresor, penerapan Proportional–Integral–Derivative Control pada accelerator, serta penguatan pengawasan SOP QC pada pergantian shift. Implementasi usulan ini diestimasikan dapat menurunkan total luas penggunaan lahan untuk WIP sebesar 8,96% dan mengurangi lead time item A sebesar 67,94% serta item D sebesar 56,8%.
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Cigarette Filter Manufacturing Companies in Indonesia are challenged in maintaining production efficiency as the result of high Work In Process (WIP) which has an impact on waiting time and lead time. This research is intended to identify and reduce waste in cell capsule production using Lean Manufacturing approach. The methods used include Value Stream Mapping for production flow mapping, Process Activity Mapping for activity classification, From-To Chart for material movement analysis, Genba Shikumi for critical waste identification and 5 Why's to find the root cause of the problem. The results showed 96.38% of the lead time was the time waiting for delivery to the customer. The production process is dominated by necessary but non-value added activities, there is an imbalance of time between processes, and indications of waste transportation in material handling. Recommendations for improvement focused on decrease the standard buffer date policy time, decrease the change order time with the application of the SMED method, adjusting counterslice standards with spare parts quality, adjusting compressor wind pressure, implementing Proportional-Integral-Derivative Control on accelerators, and reinforcing QC SOP supervision at shift changes. The implementation of this recommendation is estimated to reduce the total land use area for WIP by 8,96% and reduce the lead time of item A by 67,94% and item D by 56,8%.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Manufacturing, From to Chart, Work in Process, Filter Rokok, Lean Manufacturing, From to Chart, Work in Process, Cigarette Filter
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Efan Aditya Raya Refandy
Date Deposited:	28 Jul 2025 10:06
Last Modified:	28 Jul 2025 10:06
URI:	http://repository.its.ac.id/id/eprint/122338

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