Perencanaan Reduksi Non Value Added Activity Dan Peningkatan Safety Pada Aktivitas Pra Hingga Pasca Packaging Gula Kristal Putih Pg. Kebon Agung Kabupaten Malang

Rusdiansah, Pratama Wisnu (2022) Perencanaan Reduksi Non Value Added Activity Dan Peningkatan Safety Pada Aktivitas Pra Hingga Pasca Packaging Gula Kristal Putih Pg. Kebon Agung Kabupaten Malang. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PG. Kebon Agung Kabupaten Malang yang merupakan salah satu pabrik gula terbesar di Kota dan Kabupaten Malang memproduksi gula kristal putih hingga 130.000 ton gula setiap tahun. Untuk menunjang proses produksi, PG Kebon Agung memiliki Departemen Packer yang beroperasi sepanjang tahun untuk menyediakan produk gula Retail yang siap jual. Terdapat indikasi bahwa adanya non value added activity pada proses pra hingga pasca packaging yang dapat memperpanjang waktu proses, meningkatkan risiko bahaya terhadap produk dan pekerja yang berujung pada masalah lainnya. Guna menyelesaikan permasalahan tersebut, maka perlu adanya eliminasi atau pengurangan aktivitas non value added dengan konsep Lean serta mempertimbangkan risiko bahaya pada setiap aktivitasnya. Dengan Process Activity Mapping dan sistem HACCP yang digunakan untuk mengidentifikasi dan memetakan aktivitas, ditemukan waste dan risiko bahaya pada aktivitas pra hingga pasca packaging. Didapatkan tujuh NVA dan terpilih tiga waste kritis dari pengolahan tools Genba Shikumi yakni aktivitas penyisihan bagian yang defect ke pinggir workstation, penyisihan produk yang mengalami defect berat, dan menyisihkan GKP Retail yang telah dibungkus karton yang terjadi di tempat packaging. Sedangkan risiko bahaya kritis ditentukan dengan sistem HACCP yang hasilnya empat dari 5 lokasi ditandai sebagai Critical Control Point diantaranya Gudang A, jalanan, tempat packaging, dan Gudang D. Dari tiga waste kritis dilakukan pencarian akar penyebab terjadinya waste dan risiko bahaya dengan kombinasi 5 why’s analysis dan fishbone diagram. Hasilnya didapatkan lima root cause yaitu terkait dengan space yang kurang memadai, lokasi yang tidak sesuai, fasilitas pada workstation yang kurang menunjang, serta kurang seimbangnya aktivitas transportasi. Kemudian disusun usulan perbaikan menggunakan 5W+2H dan didapatkan empat alternatif perbaikan yang kemudian dilakukan komparasi tiap alternatifnya sesuai dengan indikator perusahaan pada aktivitas pra hingga pasca packaging. Urutan prioritas yang didapat yaitu pembuatan prosedur penyimpanan sementara menggunakan Sistem Class Based Storage, usulan penggunaan movable conveyor belt , penerapan 5S , serta pembuatan SOP dalam memonitoring kinerja mesin packer.
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PG. Kebon Agung Malang Regency, which is one of the largest sugar factories in Malang City and Regency, produces white crystal sugar up to 130,000 tons of sugar every year. To support the production process, PG Kebon Agung has a Packer Department which operates throughout the year to provide retail sugar products that are ready to be sold. This place indicates that there are non-value added activities in the pre- to post-packaging process which can increase lead time, and increase the risk of harm to products and workers which can lead to other problems. To solve these problems, it is necessary to eliminate or reduce non-value-added activities with the Lean concept and consider the risk of hazard in each activity. With Process Activity Mapping and the HACCP system used to identify and map activities, waste and hazard risks are found in pre- to post-packaging activities. Seven NVAs were obtained and three critical wastes were selected from the processing of Genba Shikumi tools, including the activity of removing defective parts to the edge of the workstation, eliminating products with severe defects, and setting aside Retail GKP that had been wrapped in cartons that occurred at the packaging site. Meanwhile, the critical hazard risk is determined by the HACCP system, with the result that four out of 5 locations are marked as Critical Control Points including Warehouse A, streets, packaging areas, and Warehouse D. From the three critical wastes, a search for the root causes of waste and hazard risk is carried out with a combination of 5 why's analysis. and fishbone diagrams. The results obtained five root causes, including those related to inadequate space, inappropriate locations, inadequate facilities at workstations, and unbalanced transportation activities. Then it was started to design a proposed improvement using 5W+2H and four alternative improvements were obtained and then compared with each other alternative according to the company's indicators in pre- to post-packaging activities. The priority order obtained is making temporary storage procedures using the Class Based Storage System, proposals for the use of movable conveyor belts, implementing 5S, and making SOPs in monitoring the performance of packer machines.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	5 why’s analysis, Genba Shikumi, , Risiko Bahaya, Sistem HACCP, Waste,
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	09 Feb 2026 05:25
Last Modified:	09 Feb 2026 05:25
URI:	http://repository.its.ac.id/id/eprint/132288

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