Peningkatan Eco-Efficiency Pada Pipa Baja Oil And Gas High Frequency Welding (HFW) Melalui Integrasi Lean Manufacturing Dan Material Circularity Indicator (MCI)

Harianto, Siens (2026) Peningkatan Eco-Efficiency Pada Pipa Baja Oil And Gas High Frequency Welding (HFW) Melalui Integrasi Lean Manufacturing Dan Material Circularity Indicator (MCI). Doctoral thesis, Institut Teknologi Sepuluh Nopember.

Text 7032201016-Dissertation.pdf - Accepted Version Restricted to Repository staff only Download (4MB) | Request a copy

Abstract

Industri baja merupakan sektor yang material- dan energy-intensive, sehinggapeningkatan efisiensi sumber daya dan pengurangan limbah menjadi kunci untuk meningkatkan eco-efficiency sekaligus mendukung transisi menuju circular economy. Penelitian ini mengusulkan integrasi Value Stream Mapping (VSM) dan Material Circularity Indicator (MCI) untuk menghubungkan perbaikan berbasis lean pada level proses dengan pengukuran circularity material yang terstandar pada level produk/sistem. Studi kasus dilakukan pada proses manufaktur pipa baja oil and gas dengan teknologi High Frequency Welding (HFW) menggunakan batas sistem gate-to-gate. VSM digunakan untuk memetakan aliran material dan informasi, mengidentifikasi pemborosan utama (waiting, defect/rework, dan overprocessing), serta merancang future state berbasis continuous improvement. MCI digunakan untuk mengevaluasi tingkat sirkularitas aliran material dengan menilai proporsi material virgin dan material sekunder serta potensi pemulihan material. Hasil penelitian menunjukkan bahwa pada kondisi awal, nilai MCI sebesar 0,18 merepresentasikan tingkat circularity yang relatif rendah akibat dominasi material primer dan besarnya limbah yang tidak dapat dipulihkan. Penerapan strategi perbaikan berbasis VSM dan skenario circular (misalnya pemanfaatan limbah produksi dan peningkatan daur ulang internal) mampu meningkatkan nilai MCI menjadi 0,22 hingga 0,32, yang mengindikasikan peningkatan signifikan dalam pemanfaatan kembali material. Dari sisi kualitas proses, tingkat defect produk yang semula mencapai 23,1% berhasil diturunkan menjadi 19,7%, yang menunjukkan perbaikan material efficiency sekaligus pengurangan pemborosan material dalam sistem produksi. Secara manajerial, temuan ini menegaskan bahwa pengendalian titik kritis proses HFW dan pengelolaan aliran material berbasis VSM dapat menjadi strategi efektif untuk meningkatkan kinerja operasional dan keberlanjutan secara simultan. Integrasi VSM–MCI memberikan kerangka evaluasi yang terukur bagi manajemen untuk memprioritaskan inisiatif perbaikan yang berdampak langsung pada pengurangan defect, peningkatan eco-efficiency, dan peningkatan circularity material pada industri pipa baja oil and gas.
=====================================================================================================================================
The steel industry is a material- and energy-intensive sector; improving resource efficiency and reducing waste is key to increasing eco-efficiency while supporting the transition to a circular economy. This research proposes integrating Value Stream Mapping (VSM) and the Material Circularity Indicator (MCI) to link lean-based improvements at the process level with standardised material circularity measurements at the product/system level. The case study was conducted on an oil and gas steel pipe manufacturing process using High Frequency Welding (HFW) technology, using gate-to-gate system boundaries. VSM was used to map material and information flows, identify key waste (waiting, defects/rework, and overprocessing), and design a future state based on continuous improvement. MCI was used to evaluate the circularity of the material flow by assessing the proportions of virgin and secondary materials and the potential for material recovery. The results showed that, under initial conditions, an MCI value of 0.18 represents a relatively low level of circularity due to the dominance of primary materials and the large amount of non-recoverable waste. Implementing VSM-based improvement strategies and circular scenarios (e.g., utilising production waste and increasing internal recycling) can increase the MCI value to 0.22- 0.32, indicating a significant increase in material reuse. In terms of process quality, the product defect rate, which initially reached 23.1%, was reduced to 19.7%, indicating improved material efficiency and reduced material waste in the production system. Managementally, these findings confirm that controlling critical points in the HFW process and managing material flows based on VSM can be an effective strategy for simultaneously improving operational performance and sustainability. The VSM-MCI integration provides a measurable evaluation framework for management to prioritise improvement initiatives that directly impact defect reduction, increased eco-efficiency, and increased material circularity in the oil and gas steel pipe industry.

Item Type:	Thesis (Doctoral)
Uncontrolled Keywords:	Pipa baja oil and gas HFW, Integrasi VSM-MCI, Defect, Eco- Efficiency, Value Stream Mapping, Material Circularity Indicator. HFW oil and gas steel pipe, VSM-MCI integration
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 66105-Doctor of Technology Management (DMT)
Depositing User:	Siens Harianto
Date Deposited:	30 Jan 2026 08:57
Last Modified:	30 Jan 2026 08:57
URI:	http://repository.its.ac.id/id/eprint/131400

Actions (login required)

View Item