Integrasi Energy Value Stream Mapping Dan Matriks Dotoli untuk Peningkatan Efisiensi Energi Pada Proses Produksi Industri Penyedap Rasa

Ramadhana, Ahmad Habib (2026) Integrasi Energy Value Stream Mapping Dan Matriks Dotoli untuk Peningkatan Efisiensi Energi Pada Proses Produksi Industri Penyedap Rasa. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Perusahaan penyedap rasa menghadapi tantangan dalam meningkatkan efisiensi energi karena penggunaan steam, listrik, dan sistem pendingin memberikan kontribusi sebesar 16% terhadap biaya Cost of Goods Manufactured (COGM). Meskipun perusahaan telah menerapkan Lean Manufacturing, implementasi perbaikan masih lebih berfokus pada peningkatan output produksi dan pengurangan defect, sedangkan pemborosan energi belum menjadi fokus utama. Penelitian ini bertujuan mengidentifikasi dan mengurangi pemborosan proses dan energi pada Unit Refinery menggunakan pendekatan Lean Manufacturing dan Energy Optimization Tools. Metode yang digunakan meliputi Energy Value Stream Mapping (Energy VSM) untuk memetakan aliran proses dan energi, Matriks Dotoli untuk menentukan critical waste, serta 5 whys untuk analisis akar penyebab waste. Hasil penelitian menunjukkan bahwa pemborosan dominan adalah waste energy pada sistem pendinginan, waste waiting dan waste defect akibat tertahannya thin broth. Usulan perbaikan dilakukan melalui integrasi energi menggunakan Heat Exchanger Network dengan memanfaatkan glutamic mother liquor-1 sebagai media pendingin internal, yang menghasilkan potensi penghematan sebesar Rp 1.229.384.800 per tahun dengan payback period 2,4 tahun. Selain itu, penerapan sistem spray ball otomatis pada Thin Broth Tank mampu menurunkan waktu pembersihan dari 49 menit menjadi 19 menit dengan potensi penghematan sebesar Rp 274,007,580.52 per tahun. Penelitian ini menunjukkan bahwa integrasi Lean Manufacturing dan Energy Optimization Tools dapat digunakan untuk mengidentifikasi pemborosan dan menyusun usulan perbaikan guna menurunkan konsumsi energi dan biaya operasional pada Unit Refinery industri penyedap rasa.
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The flavour seasoning industry faces challenges in improving energy efficiency, as the use of steam, electricity, and cooling systems contributes approximately 16% to the Cost of Goods Manufactured (COGM). Although the company has implemented Lean Manufacturing, improvement initiatives have primarily focused on increasing production output and reducing defects, while energy waste has not yet become a primary concern. This study aims to identify and reduce process and energy waste in the Refinery Unit using Lean Manufacturing and Energy Optimization Tools approaches. The methods used in this study include Energy Value Stream Mapping (Energy VSM) to map process and energy flows, the Dotoli Matrix to determine critical waste, and the 5 Whys method for root cause analysis of waste. The results indicate that the dominant wastes are energy waste in the cooling system, waiting waste, and defect waste caused by the retention of thin broth. Improvement proposals were developed through energy integration using a Heat Exchanger Network (HEN) by utilizing glutamic mother liquor-1 as an internal cooling medium, resulting in potential cost savings of IDR 1,229,384,800 per year with a payback period of 2.4 years. In addition, the implementation of an automatic spray ball system in the Thin Broth Tank reduced cleaning time from 49 minutes to 19 minutes, with potential cost savings of IDR 183,117,493 per year. This study demonstrates that the integration of Lean Manufacturing and Energy Optimization Tools can be effectively used to identify waste and formulate improvement proposals to reduce energy consumption and operational costs in the Refinery Unit of the flavor enhancer industry.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Continuous improvement, Energy Efficiency, Energy Value Stream Mapping (Energy VSM), Energy Waste, Flavor Enhancer, Lean Manufacturing.
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Ahmad Habib Ramadhana
Date Deposited:	23 Jul 2026 02:35
Last Modified:	23 Jul 2026 02:35
URI:	http://repository.its.ac.id/id/eprint/137231

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