Development Of Good Manufacturing Practice System In Beverage Manufacturing To Reduce Waste And Improve Product Quality Control

Tarigan, Elieser Lakines (2025) Development Of Good Manufacturing Practice System In Beverage Manufacturing To Reduce Waste And Improve Product Quality Control. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pengembangan sistem Good Manufacturing Practice (GMP) pada manufaktur minuman dilakukan untuk memenuhi persyaratan Food Safety Management System (FSMS) sesuai Permenprin No.75/M-IND/PER/2010 dan ISO 22000:2018. Tantangan pada masa pasca-commissioning, seperti 594 pelanggaran operasional dan 58 kasus ketidaksesuaian produk selama tahun 2024, menunjukkan kebutuhan akan perbaikan sistem. Melalui pendekatan Design Thinking dan analisis Gap terhadap 63 variabel GMP dan HACCP, serta pemetaan menggunakan Importance Performance Analysis (IPA), diidentifikasi area prioritas untuk ditingkatkan. Setelah intervensi sistem, nilai rata-rata gap menurun dari 2,74 menjadi 1,08, dan kepatuhan GMP meningkat dari 77,04% menjadi 91,48%. Hasil Root Cause Analysis dan Impact-Effort Matrix menghasilkan solusi yang efektif seperti pelatihan dan penyusunan HACCP, digitalisasi pelaporan 5R, dan pembentukan tim keamanan pangan. Uji coba sistem menunjukkan peningkatan quality conformance produk dari 99,22% menjadi 99,81%, serta penurunan kerugian tahunan dari sekitar Rp4,8 miliar menjadi sekitar Rp6,5 juta. Hal ini membuktikan bahwa desain sistem berbasis kebutuhan operasional mampu meningkatkan mutu, efisiensi, dan kepatuhan terhadap standar keamanan pangan.
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The development of a Good Manufacturing Practice (GMP) system in a beverage manufacturing facility was carried out to comply with the Food Safety Management System (FSMS) requirements based on Regulation No. 75/M-IND/PER/2010 and ISO 22000:2018. Challenges encountered during the post-commissioning phase—such as 594 operational violations and 58 cases of product non-conformities throughout 2024—indicated the urgent need for system improvement. Using a Design Thinking approach, coupled with a gap analysis on 63 GMP and HACCP variables and the Importance Performance Analysis (IPA) method, the study identified and prioritized key issues for intervention. Following the implementation of the new system, the average gap score decreased from 2.74 to 1.08, and GMP compliance improved from 77.04% to 91.48%. Root cause analysis and the Impact-Effort Matrix guided the formulation of effective solutions, including HACCP training programs & HACCP development, digitalization of 5S reporting, and the establishment of a food safety team. System testing showed improvements in product quality conformance from 99.22% to 99.81%, alongside a reduction in annual financial loss from over IDR 4.8 billion to only IDR 6.5 million. These outcomes demonstrate that a needs-based GMP system design can significantly enhance quality, efficiency, and compliance with food safety standards.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	GMP, Food Safety Management System , Design Thinking , Importance Performance Analysis, Reduce Waste
Subjects:	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:	Elieser Lakines Tarigan
Date Deposited:	07 Aug 2025 02:00
Last Modified:	07 Aug 2025 02:00
URI:	http://repository.its.ac.id/id/eprint/127866

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