Peningkatan Efisiensi Produksi Industri Furnitur Melalui Lean Manufacturing Pada Cv. Mulya Pratama Indah.

Faridzi, Salman Al (2022) Peningkatan Efisiensi Produksi Industri Furnitur Melalui Lean Manufacturing Pada Cv. Mulya Pratama Indah. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

CV. Mulya Pratama Indah merupakan salah satu perusahaan industri furnitur di Cirebon, Jawa Barat. Produk yang dihasilkan adalah meja dan kursi dengan komposisi pesanan 90% kursi dan 10% meja. Dalam menjalankan proses bisnisnya, perusahaan menerapkan sistem make to order yang di mana produksi dilakukan setelah dipesan oleh buyer. Saat ini perusahaan melakukan pengiriman ke Amerika Serikat, Afrika Selatan, Australia, dan Spanyol. Target harian yang ditetapkan oleh perusahaan saat ini adalah 200 unit produk dalam satu hari, namun dalam kondisi existing saat ini hanya mampu memproduksi 175 unit. Oleh karena itu, maka diperlukan perbaikan pada lini produksi melalui pendekatan lean manufacturing sehingga target produksi harian dapat terpenuhi. Perbaikan berpusat pada upaya mereduksi dan mengeliminasi pemborosan yang terjadi. Aliran informasi dan aliran fisik diidentifikasi untuk menggambarkan proses produksi secara umum menggunakan Value Stream Mapping. Identifikasi pemborosan yang terjadi dalam proses produksi menggunakan Waste Assessment Model untuk mengetahui peringkat waste. Peringkat waste empat tertinggi dianalisis menggunakan Root Cause Analysis (RCA) dengan tools Ishikawa Diagram dan 5 Why’s. Rancangan perbaikan yang diusulkan berdasarkan hasil Failure Mode and Effect Analysis untuk mengetahui risiko terbesar masalah dari waste. Pada kondisi existing, cycle time sebesar 3,32 menit per unit sedangkan takt time sebesar 2,73 menit per unit. Hal tersebut menyebabkan perusahaan tidak dapat memenuhi demand sehingga harus menerapkan lembur. Dalam proses produksi, terdapat 6 divisi produksi yang terdiri atas Divisi Pembahan dan Komponen, Pengeringan Komponen, Tenaga Manual dan Operator Mesin, Ampelas, Anyam, dan Packaging. Waktu produksi terpanjang berada di pengeringan komponen, sebesar 3,32 menit per unit. Bootleneck terjadi pada Divisi Pengeringan Komponen dan Tenaga Manual dan Operator Mesin karena waktu proses lebih besar daripada proses selanjutnya. Terdapat 25 hubungan antar waste dari 31 hubungan yang diidentifikasi oleh Rawabdeh (2005). Penyumbang terbesar waste untuk memunculkan waste lainnya adalah overproduction dengan persentase sebesar 19,08%, sedangkan penerima terbesar waste akibat waste lainnya adalah waiting sebesar 21,37%. Waste kritis berdasarkan WAM adalah defect, motion, process, dan inventory dengan persentase sebesar 24%, 19%, 19%, dan 14%. Berdasarkan FMEA, rancangan perbaikan terbagi menjadi tiga, yaitu perbaikan pada sistem manajemen perusahaan, operasional perusahaan, dan cycle time produksi. Berdasarkan rancangan perbaikan yang diusulkan, maka diprediksi bahwa cycle time adalah 2,7 menit per unit dan waktu tersebut kurang dari takt time yang tersedia.
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CV. Mulya Pratama Indah is one of the furniture industry companies in Cirebon, West Java. The resulting products are tables and chairs with an order composition of 90% chairs and 10% tables. In carrying out its business processes, the company applies a make-to-order system in which production is carried out after being ordered by the buyer. The company currently makes deliveries to the United States, South Africa, Australia, and Spain. The daily target set by the company is currently 200 units of product in one day, but in existing conditions, it is only able to produce 175 units. Therefore, it is necessary to improve the production line through a lean manufacturing approach so that daily production targets can be met. Improvements are centered on efforts to reduce and eliminate waste that occurs. Information flow and physical flow are identified to describe the general production process using Value Stream Mapping. Identification of waste that occurs in the production process uses the Waste Assessment Model to determine the rank of waste. The four highest waste rankings were analyzed using Root Cause Analysis (RCA) with the Ishikawa Diagram and 5 Why's tools. The proposed improvement design is based on the results of Failure Mode and Effect Analysis to find out the biggest risk of problems from waste. In the existing condition, the cycle time is 3.32 minutes per unit while the takt time is 2.73 minutes per unit. This causes the company to be unable to meet the demand so it must apply overtime. In the production process, there are 6 production divisions consisting of the Division of Materials and Components, Drying Components, Manual Power and Machine Operators, Sandpaper, Weaving, and Packaging. The longest production time is in component drying, which is 3.32 minutes per unit. Bottlenecks occur in the Component Drying Division and Manual Power and Machine Operators because the processing time is greater than the next process. There are 25 relationships between waste from 31 relationships identified by Rawabdeh (2005). The biggest contributor of waste to generate other waste is overproduction with a percentage of 19.08%, while the largest recipient of waste due to other waste is waiting at 21.37%. Critical waste based on WAM is the defect, motion, process, and inventory with percentages of 24%, 19%, 19%, and 14%. Based on the FMEA, the improvement plan is divided into three, namely improvements to the company's management system, company operations, and production cycle time. Based on the proposed improvement design, it is predicted that the cycle time is 2.7 minutes per unit and this time is less than the available takt time.

Item Type:	Thesis (Other)
Additional Information:	RSKe 627.98 Alf a-1 2022
Uncontrolled Keywords:	Waste, Value Stream Mapping, Waste Assessment Model (WAM), Root Cause Analysis, dan Failure Mode and Effect Analysis. Waste, Value Stream Mapping, Waste Assessment Model (WAM), Root Cause Analysis, and Failure Mode and Effect Analysis.
Subjects:	T Technology > TC Hydraulic engineering. Ocean engineering > TC1665 Offshore structures--Materials.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	12 May 2026 03:58
Last Modified:	12 May 2026 03:58
URI:	http://repository.its.ac.id/id/eprint/133155

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