Perbaikan Proses Produksi Menggunakan Pendekatan Lean Manufacturing (Studi Kasus : Unit Produksi Urea Pabrik-4 PT. Pupuk Kalimantan Timur)

Kusuma, Yudha Setya (2017) Perbaikan Proses Produksi Menggunakan Pendekatan Lean Manufacturing (Studi Kasus : Unit Produksi Urea Pabrik-4 PT. Pupuk Kalimantan Timur). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Unit Produksi Urea Pabrik-4 merupakan salah satu unit pabrik yang memproduksi pupuk Urea non Subsidi pada PT Pupuk Kaltim. Berdasarkan hasil observasi awal dengan menggunakan data produksi pada tahun 2016, dapat diketahui bahwa proses produksi pada unit pabrik tersebut memiliki beberapa permasalahan yang dibuktikan dengan nilai kapabilitas proses sebesar 0,45, presentase produk Urea non subsidi dengan kandungan di luar batas spesifikasi sebesar 47%, serta adanya pengembalian dari gudang produk jadi berupa karung pupuk pecah sebesar 0.5% dari total produksi tahun 2016. Penelitian ini dilakukan untuk mengidentifikasi serta menganalisa akar penyebab permasalahan yang ada pada proses produksi serta memberikan usulan rekomendasi perbaikan menggunakan pendekatan lean manufacturing. Tahap yang dilakukan dalam penelitian ini dimulai melalui tahap identifikasi kondisi eksisting melalui pengumpulan data dengan menggunakan tools, antara lain SIPOC Diagram, Big Picture Mapping, Activity Classification Diagram, serta penyebaran kuesioner waste berbasis E-DOWNTIME. Kuesioner tersebut disebarkan kepada 4 expert yang ada di perusahaan yang kemudian diolah menggunakan BORDA Voting Method hingga didapatkan 2 waste kritis, yaitu defect dan waiting. Selanjutnya, dilakukan identifikasi serta analisia terhadap akar permasalahan pada waste kritis dengan menggunakan tools Root Cause Analysis (RCA). Setelah itu, dirancang kuesioner konsep Analisa Risiko yang diisi oleh salah satu expert di perusahaan untuk menentukan prioritas penanganan akar penyebab waste kritis yang terjadi dengan menilai tingkat consequence dan likelihood dari masing-masing akar permasalahan hingga didapatkan nilai risk rating. Dari hasil penelitian didapatkan 11 akar permasalahan yang memiliki nilai risk rating tertinggi yang dapat diselesaikan dengan diusulkannya rekomendasi perbaikan berupa investasi alat pada gudang penyimpanan produk jadi, yaitu Pallet Rack dan adanya perancangan penjadwalan preventive maintenance dengan mempertimbangkan nilai penghematan yang dapat diperoleh pada pengimplementasiannya. Melalui kedua rekomendasi perbaikan yang diusulkan, perusahaan mampu menekan biaya pemborosan serta meningkatkan daya saing perusahaan pada pasar pupuk internasional. ========================================================== Urea Production Unit-4 Factory is one unit of factory that produces non subsidized Urea fertilizer at PT Pupuk Kaltim. Based on the results of preliminary observation using production data in 2016, it can be seen that the production process at the factory unit has several problems which is proved by the process capability value of 0.45, the percentage of non subsidized Urea product with content beyond the specification limit of 47% As well as the return of the finished product warehouse in the form of a broken fertilizer sack of 0.5% of the total production in 2016. This research was conducted to identify and analyze the root cause of existing problems in the production process and to propose improvement recommendations using lean manufacturing approach. The stages carried out in this research started through identification of existing condition through data collecting by using tools, such as SIPOC Diagram, Big Picture Mapping, Activity Classification Diagram, and spreading of E-DOWNTIME based waste questionnaire. The questionnaire was distributed to 4 experts in the company which then processed using BORDA Voting Method to get 2 critical waste, that is defect and waiting. Furthermore, identification and analysis of the root of the problem in critical waste using the Root Cause Analysis (RCA) tools are used. After that, the Risk Analysis Concept questionnaire was designed by one of the experts in the company to determine the priority of handling the root cause of critical waste that occurred by assessing the level of consequence and likelihood from each root of the problem to get the value of risk rating. From the research result, there are 11 root causes that have the highest risk rating that can be solved by proposed repair recommendation in the form of investment of tool at storage warehouse of finished product, that is Pallet Rack and the design of preventive maintenance scheduling by considering the saving value that can be obtained at its implementation. Through both proposed improvement recommendations, the company was able to reduce the cost of waste and increase the competitiveness of the company in the international fertilizer market.

Item Type: Thesis (Undergraduate)
Additional Information: RSI 658.562 Kus p
Uncontrolled Keywords: Borda Voting Method, Konsep Analisa Risiko, Lean Manufacturing, Urea
Subjects: T Technology > T Technology (General)
T Technology > TJ Mechanical engineering and machinery > TJ217.6 Predictive Control
T Technology > TS Manufactures > TS156 Quality Control
T Technology > TS Manufactures > TS167 Costs, Industrial
Divisions: Faculty of Industrial Technology > Industrial Engineering > (S1) Undergraduate Theses
Depositing User: Yudha Setya Kusuma
Date Deposited: 27 Nov 2017 06:57
Last Modified: 27 Nov 2017 06:57
URI: http://repository.its.ac.id/id/eprint/46431

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