Implementasi Environmental Value Stream Mapping untuk Perbaikan Efisiensi pada Proses Fabrikasi Kapal

Irfansyah, Ardelia Farhanah (2026) Implementasi Environmental Value Stream Mapping untuk Perbaikan Efisiensi pada Proses Fabrikasi Kapal. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Industri galangan kapal memiliki karakteristik proses produksi yang kompleks dan saling bergantung, sehingga berpotensi menimbulkan pemborosan operasional (lean waste) sekaligus pemborosan lingkungan (environmental waste). Penelitian ini bertujuan untuk mengidentifikasi environmental waste pada proses fabrikasi material profil L Blok 213 di PT XYZ, menganalisis akar penyebab permasalahan, serta merumuskan usulan perbaikan menggunakan pendekatan Environmental Value Stream Mapping (EVSM) dan Process Activity Mapping (PAM). Berdasarkan penyusunan current state EVSM, ditemukan total lead time aktual yang sangat tinggi sebesar 512,05 jam. Identifikasi waste kritis mendeteksi adanya kehilangan 3 kg steel shot akibat kebocoran mekanis mesin shot blasting yang memicu downtime 122 menit serta total energy waste berantai sebesar 23,59 kWh pada mesin blasting dan cat primer. Selain itu, tata letak staging area yang tidak linear memicu transport waste dengan konsumsi energi crane sebesar 13,22 kWh, serta terjadi idle berlebih pada awal shift akibat diskoneksi jadwal logistik material. Analisis akar penyebab menggunakan Fishbone Diagram menunjukkan inefisiensi didominasi oleh faktor perawatan mesin yang bersifat korektif, ketiadaan sistem interlock/sensor otomatis, dan layout staging penataan manual. Melalui perumusan usulan perbaikan 5W1H, direkomendasikan standardisasi pre-operation checklist dengan thickness gauge, pengaturan ulang tata letak staging area menjadi aliran linear, serta sinkronisasi jadwal start-up mesin berdasarkan kesiapan material. Visualisasi future state EVSM menunjukkan proyeksi perbaikan yang signifikan, di mana total lead time berhasil dipangkas secara drastis sebesar 80,63% menjadi 99,18 jam, disertai dengan eliminasi energy waste non-produktif dan reduksi transportasi material secara optimal.
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The shipbuilding industry is characterized by complex and interdependent production processes, which highly potential to generate both operational inefficiencies (lean waste) and environmental impacts (environmental waste). This study aims to identify environmental waste in the fabrication process of L-profile (angle bar) materials for Block 213 at PT XYZ, analyze the underlying root causes, and formulate improvement recommendations utilizing the Environmental Value Stream Mapping (EVSM) and Process Activity Mapping (PAM) approaches. Based on the development of the current state EVSM, a significantly prolonged actual total lead time of 512.05 hours was identified. Critical waste identification detected a loss of 3 kg of steel shot due to mechanical leakage in the shot blasting machine, which triggered 122 minutes of downtime and a consecutive total energy waste of 23.59 kWh across the blasting and primer painting machines. Furthermore, a non-linear staging area layout induced a cumulative transport waste consuming 13.22 kWh of crane energy, alongside excessive idling at the beginning of shifts due to a disconnection in material logistics scheduling. Root cause analysis via Fishbone Diagrams indicated that inefficiencies were predominantly driven by corrective machine maintenance practices, the absence of automated interlock/sensor systems, and manual positioning within the staging layout. Through 5W1H-based improvement formulations, this research recommends the standardization of pre-operation checklists using thickness gauges, the reconfiguration of the staging area layout into a linear flow, and the synchronization of machine start-up schedules based on material readiness. Visualizations of the future state EVSM demonstrate substantial improvements, projecting a drastic 80.63% reduction in total lead time to 99.18 hours, accompanied by the elimination of non-productive energy waste and the optimization of material transportation.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Environmental Value Stream Mapping, fabrikasi kapal, Green Lean Manufacturing, pemborosan lingkungan Environmental Value Stream Mapping, environmental waste, Green Lean Manufacturing, ship fabrication
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Ardelia Farhanah Irfansyah
Date Deposited:	01 Aug 2026 01:59
Last Modified:	01 Aug 2026 01:59
URI:	http://repository.its.ac.id/id/eprint/141298

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