Peningkatan Efisiensi Pada Proses Pembuatan Bir (Brewing) Dengan Metode Lean Manufacturing Di Pt Xyz

Faisal, Faisal (2022) Peningkatan Efisiensi Pada Proses Pembuatan Bir (Brewing) Dengan Metode Lean Manufacturing Di Pt Xyz. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Untuk menjalankan bisnisnya di era “New Normal” akibat pandemi Covid-19, perusahaan dihadapkan dengan berbagai tantangan salah satunya strategi menurunkan atau menghilangkan potensi pemborosan (waste) yang terjadi di lini produksi sehingga dapat meningkatkan efisiensi dan mengurangi biaya produksi. Begitu juga yang terjadi pada PT XYZ yaitu industri yang memproduksi bir yang berlokasi di Jawa Timur. Dalam observasi awal yang diperoleh, terjadi pemborosan di lini produksi proses pembuatan bir (brewing). Hal ini menyebabkan perusahaan mengalami kerugian di lini produksi proses pembuatan bir sebesar Rp.867.257.500 selama tahun 2021. Penelitian ini akan membantu menyelesaikan permasalahan yang dihadapi perusahaan melalui pendekatan lean manufacturing. Pertama, pemborosan diidentifikasi melalui value stream mapping dan dengan menggunakan process activity mapping (PAM), borda count method untuk mengidentifikasi pemborosan (waste) kritis yang ada. Kemudian menggunakan metode root cause analysis (RCA) untuk menemukan akar penyebab pemborosan (waste) yang terjadi. Sehingga diharapkan dapat memberikan rekomendasi untuk menghilangkan beberapa pemborosan, serta mengoptimalkan kinerja sistem di lini produksi proses pembuatan bir (brewing). Berdasarkan hasil penelitian, diketahui bahwa tiga pemborosan (waste) yang sering terjadi yaitu overprocessing, inventory, dan movement. Sehingga untuk mengurangi pemborosan tersebut, diberikan beberapa saran yang memiliki beberapa keuntungan seperti penghematan air 1.157 hL/ tahun, mengurangi extract losses sebesar 3.066 kg extract/ tahun, menghilangkan kelebihan stock mature beer 4,7% dari planning stock saat ini, serta mengurangi aktivitas necessary non value added (NNVA) sebesar 14,5% dari total necessary non value added (NNVA) di proses produksi pembuatan bir (brewing) PT XYZ.
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In order to conduct business in the "new normal" era due to the Covid-19 pandemic, companies face various challenges, one of them is strategies to reduce or eliminate potential waste from production, improve efficiency, and reduce production costs. The same happens with PT XYZ which is a beer production company located in East Java. According to preliminary observations, there are waste in the production line of the brewing process. This caused the company to suffer losses in the production line of brewing process approximately Rp.867.257.500,- in 2021. This research will help to solve these problems through lean manufacturing methods. First, various waste are identified through value stream mapping, process activity mapping (PAM), borda count method. Then use the root cause analysis (RCA) to find the cause of the waste that is taking place. Then make the recommendations to the company to avoid waste and optimize system performance in the brewing process. According to the research result, it was found that three critical wastes, namely overprocessing, inventory and movement. In order to reduce this critical wastes, recommendations are made which have several potential advantages such as potential water savings approximately 1,157 HL/year, extract losses savings around 3,066 kg extract/year, elimination of 4.7% of excess mature beer inventory from current planned inventory, and 14.5% reduction in necessary non-value added (NNVA) activities in the brewing process of PT XYZ.

Item Type:	Thesis (Masters)
Additional Information:	RTMT 658.5 Fai p-1 2022
Uncontrolled Keywords:	Lean manufacturing, value stream mapping, process activity mapping (PAM), borda count method, root cause analysis (RCA).
Subjects:	T Technology > T Technology (General)
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Mr. Marsudiyana -
Date Deposited:	08 Jul 2026 01:53
Last Modified:	08 Jul 2026 01:53
URI:	http://repository.its.ac.id/id/eprint/134484

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