Upaya Reduksi Pemborosan Pada Proses Produksi Wardrobe di UMKM Mebel Menggunakan Konsep Lean Manufacturing

Syahbana, Demas Daffa (2022) Upaya Reduksi Pemborosan Pada Proses Produksi Wardrobe di UMKM Mebel Menggunakan Konsep Lean Manufacturing. Other thesis, Institut Teknologi Sepuluh Nopember.

Text 02411840000173-Undergraduate_Thesis.pdf Restricted to Repository staff only Download (3MB) | Request a copy

Abstract

Perusahaan Mebel ABC merupakan industri kecil-menengah yang memproduksi Furnitur di Kota Madiun. Jenis produk yang dihasilkan dibedakan menjadi 2 (dua) jenis, yaitu knockdown dan fully assembled. Perusahaan ABC tersebut mendapatkan keluhan yang didominasi dari pelanggan produk fully assembled. Hasil wawancara dengan pihak perusahaan diketahui keluhan diakibatkan produk yang defect dan selain itu juga terdapat indikasi adanya pemborosan/waste seperti belum adanya standardisasi pekerjaan serta pergerakan dari operator yang terlalu banyak. Berdasarkan hal tersebut, tujuan dari penelitian ini adalah mengidentifikasi dan mengurangi aktivitas yang tidak bernilai tambah dengan menggunakan konsep Lean Manufacturing. Penelitian ini berawal dari pembuatan Operation Process Chart (OPC), diteruskan dengan pemetaan aliran nilai menggunakan Value Stream Mapping (VSM), dan juga dilanjutkan dengan menggunakan pemetaan seluruh aktivitas pada proses produksi dengan metode Process Activity Mapping (PAM). Dengan menggunakan Genba Shikumi, ditemukan beberapa waste kritis yang ada selama proses produksi antara lain mengelompokkan hasil perakitan komponen, mengelompokkan komponen dari hasil pendempulan, dan penataan kertas karton sementara. Setelah itu, dilakukan analisis menggunakan 5 Whys untuk mengetahui akar penyebab waste kritis. Akar penyebab waste kritis tersebut antara lain perusahaan memiliki budaya organisasi yang lemah, tidak ada instruksi kerja, tidak ada alat yang membantu proses kerja secara optimal, tempat kerja yang tidak terorganisasi dengan baik, dan tidak ada kebijakan terkait peraturan sebelum melakukan kontrak dengan customer. Rekomendasi perbaikan disusun berdasarkan akar penyebab waste kritis yang telah ditemukan. Kemudian, pada tahap Modified Lean Matrix yang telah mempertimbangkan tingkat efektivitas dan tingkat kesulitan rekomendasi diperoleh bahwa hasil rekomendasi pembuatan instruksi kerja sebagai peringkat pertama.
==================================================================================================================================
ABC Furniture Company is a small-medium industry that produces furniture in Madiun City. The types of products produced are divided into 2 (two) types, there are knockdown and fully assembled. The ABC company received complaints, which were dominated by customers of fully assembled products. The results of interviews with the company revealed that complaints were caused by defective products and besides that there were also indications of waste such as the absence of standardization of work and too many movements from operators. Based on these results, the purpose of this study is to identify and reduce non-value added activities by using the concept of Lean Manufacturing. This research started with creating the Operation Process Chart (OPC), continued with mapping of value streams using Value Stream Mapping (VSM), and also continued by mapping all activities in the production process using the Process Activity Mapping (PAM) method. By using Genba Shikumi, several critical wastes were found during the production process, including grouping the assembly results of components, grouping components from putty products, and arranging temporary cardboard. After that, an analysis was carried out using 5 Whys to find out the root causes of critical waste. The root causes of critical waste include the company having a weak organizational culture, no work instructions, no tools that help the work process optimally, a workplace that is not well organized, and no policies related to regulations before entering into a contract with a customer. Recommendations for improvement are based on the root causes of critical waste that have been found. Then, at the Modified Lean Matrix stage which has considered the effectiveness and difficulty level of the recommendations, it is obtained that the recommendation for making work instructions is the first rank.

Item Type:	Thesis (Other)
Additional Information:	RSI 658.5 Sya u-1 2022 3100022094612
Uncontrolled Keywords:	Genba Shikumi, Industri manufaktur mebel, Lean assessment matrix, Lean manufacturing, 5 Whys
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Anis Wulandari
Date Deposited:	16 Oct 2025 01:48
Last Modified:	16 Oct 2025 01:48
URI:	http://repository.its.ac.id/id/eprint/128599

Actions (login required)

View Item