Penerapan Metode Lean Untuk Mengurangi Pemborosan Pada Proses Produksi Corrugated Carton Box Pt. Src

Putranto, Johni Harius (2007) Penerapan Metode Lean Untuk Mengurangi Pemborosan Pada Proses Produksi Corrugated Carton Box Pt. Src. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses Produksi Corrugated Carton Box dengan sistem job order system production menuntut kesesuaian terhadap kualitas yang dikehendaki pelanggan. Terjadinya Over Production, Waiting, Transportation, Inappropriate Processing, Unnecessary Inventory, Unnecessary Motion, dan Defect merupakan hal yang harus diminimalisir dalam rangkaian prosesnya, mengingat sifat dari job order production yang berhenti dan berganti saat proses satu selesai kemudian digantikan proses lainnya.

Metode LEAN dilaksanakan melalui Process Value Analysis, Value Stream Analysis untuk menghasilkan rantai proses dengan pencapaian kinerja yang lebih baik. VALSAT dalam metode LEAN menyediakan Process Activity Mapping, Supply Chain Response Matrix, Production Variety Funnel, Quality Filter Mapping, Demand Amplification Mapping, Decision Point Analysis, dan Physical Structure untuk dipilih dalam perbaikan kinerja. Perhitungan matrix dengan melakukan pengolahan terhadap penilaian kuisioner dari pihak manajemen pada obyek dalam menilai rantai proses dilakukan menggunakan AHP untuk penentuan pemilihan metode VALSAT yang tepat. Identifikasi Value Added Activity, Non-Value Added Activity, Necessary Non-Value Added Activity dilakukan dalam penerapan VALSAT, sehingga diketahui beberapa hal yang harus dikurangi atau diperbaiki dalam rantai proses produksi.

Hasil penelitian melalui metode AHP mengemukakan bahwa pemborosan (waste) jenis defect menjadi prioritas pihak manajemen dan pengendali untuk dilakukan perbaikan. Pada penentuan VALSAT, terpilih Process Activity Mapping (PAM) dan Quality Filter Mapping (QFM) sebagai alat yang tepat dalam mengurangi atau bahkan menghilangkan pemborosan yang terjadi di PT. SRC. Pada analisa PAM perbaikan yang direkomendasikan antara lain: menata jadwal dan alokasi waktu kerja serta mengatur peletakan bahan pembantu dan peralatan. Work Sampling digunakan pula untuk melakukan pengukuran kerja yang dilakukan, dengan rekomendasi perbaikan meliputi: mengurangi allowance waktu kerja, mempersingkat waktu setting mesin, mengoptimalkan jam kosong, dan mengurangi terjadinya defect produksi. Analisa QFM mengemukakan rekomendasi pemakaian bahan baku dan pembantu yang sesuai jenis, spesifikasi dan kualitas.
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The job order system at corrugating carton box process is fully demanded by customer have highly need in focus on quality. Based on job order typical process, Over Production, Waiting, Transportation, Inappropriate Processing, Unnecessary Inventory, Unnecessary Motion, and Defect there are potentially occur in line process must be minimized.

Lean Method accelerate by Process Value Analysis, which is the Value Stream Analysis is involved to produce the better chain process of working. In Lean method, VALSAT have tools to choose in order to increasing work performance, there are Process Activity Mapping, Supply Chain Response Matrix, Production Variety Funnel, Quality Filter Mapping, Demand Amplification Mapping, Decision Point Analysis, and Physical Structure. The most suitable VALSAT tool chosen by applying AHP calculating matrix for performance questioner mark Value Added Activity, Non-Value Added Activity, and Necessary Non-Value Added Activity identification also include in applying VALSAT for knowing all things that can eliminate or reducing at process line.

The AHP calculate method showing that waste priority reducing start in defect. The tools for reducing or even eliminating waste at PT. SRC process are Process Activity Mapping (PAM) and Quality Filter Mapping (QFM). Work scheduling and manufacturing lay out are recommended in Process Activity Mapping (PAM). Applying work sampling showed that reducing defect, allowance time, shortening setting time and maximizing working time are the point to get better performance. Choosing suitable that fit in to specification standard is recommended solution for increasing performance from QFM Analysis.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Lean Thinking, Wastes, Aliran Proses, V ALSAT, AHP. , PT. SRC Lean Thinking, Wastes, Process Flow, VALSAT, AHP
Subjects:	T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions:	Faculty of Business and Management Technology > Management Technology > 61101-(S2) Master Thesis
Depositing User:	magang .
Date Deposited:	21 Sep 2026 01:53
Last Modified:	21 Sep 2026 01:53
URI:	http://repository.its.ac.id/id/eprint/144708

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