Identifikasi Waste dengan Metode Waste Assessment Model dalam Penerapan Lean Manufacturing untuk Perbaikan Proses Produksi (Studi Kasus pada Proses Produksi Sarung Tangan)

Alfiansyah, Reza (2018) Identifikasi Waste dengan Metode Waste Assessment Model dalam Penerapan Lean Manufacturing untuk Perbaikan Proses Produksi (Studi Kasus pada Proses Produksi Sarung Tangan). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. X merupakan perusahaan yang bergerak pada bidang manufaktur sarung tangan rajut. Sarung tangan rajut merupakan sarung tangan yang digunakan sebagai Alat Pelindung Diri (APD) pada industri perkebunan, perikanan maupun kegiatan konstruksi. Dalam proses produksinya, masih ditemukan berbagai indikasi waste yang menyebabkan menurunnya efisensi dan efektivitas proses produksi. Salah satu permasalahan terbesar adalah defect dengan presentase defect BS diatas 4.6% dan defect afkir sebesar 1.813%. Selain itu, ditemukan berbagai indikasi waste terkait waste waiting, transportation dan berbagai waste lainnya. Adanya berbagai waste tersebut menyebabkan munculnya potential profit loss yang hilang bagi perusahaan. Penelitian ini bertujuan untuk mengeliminasi waste pada proses produksi sarung tangan di PT. X dengan implementasi metode lean manufacturing. Langkah awal penelitian dilakukan dengan identifikasi proses produksi dan waste menggunakan Operation Process Chart (OPC), Value Stream Mapping (VSM) dan Waste Assessment Model (WAM). Berdasarkan WAM, diketahui 3 waste kritis yaitu defect, waiting dan transportation. Selanjutnya dilakukan analisis akar masalah dengan Root Cause Analysis (RCA) 5Why’s dan mencari nilai risiko kegagalan menggunakan Failure Mode and Effect Analysis (FMEA). FMEA dikategorikan kritis ketika nilai RPN ≥240 untuk kemudian dilakukan analisis perancangan rekomendasi perbaikan. Terdapat 3 alternatif perbaikan yaitu pengurangan defect proses produksi, perbaikan sistem serta perbaikan sistem manajemen dan produksi. Pemilihan alternatif dilakukan dengan menggunakan value management. Berdasarkan value management, didapatkan kombinasi alternatif perbaikan terbaik adalah alternatif 1 dan 2. =========================================================================== PT. X is one of the company that works in the field of knit gloves manufacturing. Kni t glove is applied as safety equipment and many are used in plantation industry, fishery as well as construction activities. T here could still be found many indications of waste that result in the reduction of efficiency and effectivity of the production p rocess. One of the major problem is defect with the percentage of BS defect above 4.6% and rejected defect as much as 1.813%. Furthermore, it is also found the waste indication of waiting, transportation and various other wastes. Due to the presence of the se wastes, there are chances of potential profit loss from the company. This research has the objective to eliminate the wastes on the production process of knit glove in PT. X by implementing lean manufacturing method. The first step of this research is d one by identifying the production process and waste using Operation Process Chart (OPC), Value Stream Mapping (VSM) and Waste Assessment Model (WAM). Based on the WAM result, it can be known the three most critical waste, i.e. defect, waiting and transport ation. Then, analysis is done on the root of the problem by applying Root Cause Analysis (RCA), 5 Why’s and searching the failure risk score using Failure Mode and Effect Analysis (FMEA). The score is categorized as critical when the value of RPN ≥240 and further analysis is done to design the recommendation of improvement. There are 3 alternatives of improvement i.e. the reduction of production process defects , refinement of the maintenance system and refinement in production and management system . Then, it calculate with value management to choose best alternative. The best combination of alternatives of improvement are alternative 1 and 2.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: 5 Why’s, Failure Mode and Effect Analysis (FMEA), Lean Manufacturing, Value Management, Value Stream Mapping (VSM), Waste Assessment Model (WAM).
Subjects: T Technology > TJ Mechanical engineering and machinery > TJ230 Machine design
T Technology > TS Manufactures > TS156 Quality Control. QFD
T Technology > TS Manufactures > TS167 Costs, Industrial
Divisions: Faculty of Industrial Technology > Industrial Engineering > (S1) Undergraduate Theses
Depositing User: Reza Alfiansyah
Date Deposited: 27 Feb 2018 03:54
Last Modified: 27 Feb 2018 03:54
URI: http://repository.its.ac.id/id/eprint/49410

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