Peningkatan Produktivitas Perusahaan Dengan Perbaikan Proses Produksi Menggunakan Metode Lean Six Sigma Dan FMEA

Saladin, Muhammad (2025) Peningkatan Produktivitas Perusahaan Dengan Perbaikan Proses Produksi Menggunakan Metode Lean Six Sigma Dan FMEA. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Dalam industri Fast Moving Consumer Goods, menuntut efisiensi dalam proses produksinya, Pada produk sabun cair, tingkat produktivitas masih cukup rendah karena banyaknya waste selama proses produksi. Penelitian ini bertujuan untuk meningkatkan produktivitas pada proses packaging dengan meminimalkan waste menggunakan gabungan metode Lean Six Sigma dan Failure Mode and Effects Analysis (FMEA). Lean Six Sigma digunakan untuk mengidentifikasi waste yang terjadi selama proses produksi, sedangkan FMEA digunakan untuk menganalisis potensi kegagalan dan memprioritaskan perbaikan failure. Analisis menunjukan bahwa waste seperti defect rate, downtime mesin yang tidak terkontrol, serta ketidakseimbangan dalam aliran produksi. Selanjutnya, Failure Mode and Effects Analysis (FMEA) digunakan untuk mengidentifikasi bahwa defect berupa kebocoran kemasan adalah waste paling berisiko dalam departemen packaging. Mesin yang breakdown mengakibatkan kesalahan dalam labelling produk. Ketidakseimbangan dalam aliran produksi mengakibatkan waktu tunggu yang lama. Hasil rekomendasi perbaikan mampu meningkatkan level sigma dari 3.2 menjadi 4.5. Persentase OEE menjadi 85% dan mengurangi lead time produksi sebanyak 1.74 jam. Penelitian ini membuktikan bahwa gabungan pendekatan Lean Six Sigma dan FMEA mampu secara efektif meningkatkan produktivitas industri sabun cair.===================================================================================================================
The Fast Moving Consumer Goods industry demands efficiency in its production process. For liquid soap products, productivity levels are still quite low due to the large amount of waste during the production process. This study aims to increase productivity in the packaging process by minimizing waste using a combination of Lean Six Sigma and Failure Mode and Effects (FMEA) methods. Lean Six Sigma is used to identify waste that occurs during the production process, while FMEA is used to analyze potential failures and prioritize failure repairs. The analysis shows that waste such as defect rates, uncontrolled machine downtime, and imbalances in the production flow. Futhermore, Failure Mode and Effects Analysis (FMEA) is used to identify that defects in the form of packaging leaks are the most risky waste in the packaging department. Machine breakdowns results in errors in products labeling. Imbalances in the production flow result in long waiting times. The results of the improvement recommendations were able to increase the sigma level from 3.2 to 4.5. The OEE percentage became 85%, and reduced production lead time by 1.74 hours. This study proves that the combination of the Lean Six Sigma and FMEA approaches can effectively increase the productivity of the liquid soap industry.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Lean Six Sigma, FMEA, Produktivitas Manufaktur, Departemen Packaging, Perusahaan Sabun Cair, Lean Six Sigma, FMEA, Manufacturing Productivity, Packaging Department, Liquid Soap Company
Subjects:	T Technology > TS Manufactures T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Muhammad Saladin
Date Deposited:	05 Aug 2025 03:25
Last Modified:	05 Aug 2025 03:25
URI:	http://repository.its.ac.id/id/eprint/125839

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