Minimasi waste dan lead time pada proses produksi leaf spring dengan pendekatan lean manufacturing

Madaniyah, Riza Nur (2017) Minimasi waste dan lead time pada proses produksi leaf spring dengan pendekatan lean manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Leaf Spring merupakan salah satu komponen sistem suspensi kendaraan. Dalam memproduksi leaf spring, perusahaan amatan mengalami beberapa permasalahan seperti terjadinya internal defect dan complain customer selama tahun 2016. Rata-rata internal defect per bulan pada perusahaan spring amatan mencapai 4.01%. Hal ini tidak sejalan dengan target yang ditentukan perusahaan yakni sebesar 1.7%. Selain itu, customer complain sepanjang tahun 2016 juga tidak sejalan dengan target perusahaan untuk mencapai zero complain customer. Permasalahan internal defect dan complain customer menyebabkan menurunnya tingkat kepercayaan konsumen, meningkatnya biaya tak terduga serta menurunnya profit perusahaan. Internal defect dan complain customer mengindikaskan terdapatnya permasalahan dalam proses produksi leaf spring. Sehingga, penelitian ini bertujuan untuk mengidentifikasi waste, menganalisis akar penyebab permasalahan pada proses produksi multi leaf spring lokal, dan menurunkan lead time proses produksi multi leaf spring lokal, serta selanjutnya memberikan rekomendasi perbaikan dengan pendekatan lean manufacturing. Langkah yang dilakukan dalam penelitian ini dimulai dari identifikasi kondisi existing serta identifikasi waste menggunakan tools value stream mapping, value stream analysis tools, dan waste assessment model. Berdasarkan hasil waste assessment model, didapatkan 3 waste kritis yakni defect, inventory dan waiting. Selanjutnya dilakukan analisis akar permasalahan pada waste kritis dengan menggunakan Root Cause Analysis. Setelah itu, dirancang kuesioner Failure Mode and Effect Analysis untuk menilai tingkat severity, occurrence, dan detection dari masing-masing akar penyebab permasalahan hingga diperoleh nilai Risk Priority Number (RPN). 4 akar permasalahan yang memiliki nilai RPN tertinggi diberikan rekomendasi perbaikan untuk dapat meminimalkan terjadinya waste, sehingga produktivitas perusahaan dapat meningkat. Selain meminimumkan terjadinya waste, dilakukan evaluasi terhadap alur proses produksi multi leaf spring lokal sehingga dihasilkan future state value stream mapping. Future state value stream mapping berkontribusi terhadap penurunan lead time sebesar 76.67 menit (8.50%) dan penurunan delay sebesar 235.02 menit (36.06%). ================================================================= Leaf spring is a component of vehicle suspension system. In producing leaf spring, observed company encounter some problems such as internal defect and customer complaint during 2016. Per month average of internal defect at observed spring company reach 4,01%. These result is not match with the target set by the company which is 1,7%. Otherwise, customer complaint during 2016 also not in line with the target to achieve zero customer complaint. Internal defect and customer complaint problems lead to a decreased levels of customer trust, rising unexpected cost and decreased corporate profits. Internal defect and customer complaint indicates that there is a problem in the leaf spring production process. So, this study aims to identify the waste, analyze the root cause of the problem, and decrease the lead time of local multi leaf spring production process, and further provides improvement recommendations by using lean manufacturing approach. The steps taken in this research starts from the identification of existing conditions and the identification of waste using value stream mapping, value stream analysis tools, and waste assesment model. Based on the results of waste assesment model, obtained 3 critical waste that is defect, inventory and waiting. Next, the root cause at critical waste analyzed using root cause analysis method. after that, designed a failure mode and effect analysis questionnaire to asses the level of severity, occurance and detection of each root cause of the problem to obtain the value of risk property number (RPN). 4 of the root problems that has the highest RPN value is given improvement recommendation to minimize the waste, so that the productivity of the company increases. in addition of minimizing of waste, an evaluation of local multi lead spring production flow process is done resulting future state value stream mapping. future state value stream mapping contributes to a decrease in lead time by 76,67 minutes (8.50%) ans decrease in delay by 235,02 minutes (36.06%).

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Lean Manufacturing, Risk Priority Number (RPN), Root Cause Analysis (RCA), Value Stream Mapping (VSM), Waste Assessment Model
Subjects: T Technology > TS Manufactures
T Technology > TS Manufactures > TS156 Quality Control
Divisions: Faculty of Industrial Technology > Industrial Engineering > (S1) Undergraduate Theses
Depositing User: Riza Nur Madaniyah
Date Deposited: 02 Oct 2017 02:41
Last Modified: 02 Oct 2017 02:41
URI: http://repository.its.ac.id/id/eprint/43665

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