Sari, Hesti Mustika (2015) Implementasi Pendekatan Lean Untuk Perbaikan Proses Produksi Biji Plastik Berwarna pada PT.X. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Berdasarkan wawancara dengan pihak PT. X terdapat beberapa permasalahan
seperti pengulangan proses pengeringan, pekerja dan mesin yang menganggur,
juga kesulitan pemindahan material karena penempatan bahan yang kurang rapi,
yang merupakan permasalahan proses produksi yang perlu dianalisa lebih lanjut
dan dilakukan perbaikan. Untuk perbaikan atas permasalahan tersebut pada
penelitian ini digunakan pendekatan Lean, untuk mengidentifikasi aktivitas nonvalue
adding, waste kritis, beserta akar penyebab utamanya, dan usulan perbaikan
melalui value analysis sehingga dapat meningkatkan performansi proses produksi
dengan pengeluaran biaya yang lebih efektif dan efisien. Dari penelitian ini
diketahui bahwa 5,56 % dari production lead time merupakan waktu proses yang
bukan digunakan untuk value-adding activities, lalu tiga waste kritis diantara 7
waste dalam konsep Lean adalah kategori Delay & Waiting dengan bobot 22,6 %,
Unnecessary Motion 20,2%, dan Inappropriate Processing 19%. Selain itu root
cause kritis yang diprioritaskan adalah keahlian dan pengalaman pekerja, kondisi
pekerja yang kurang optimal, sarana perawatan bahan selama pengiriman dan
penyimpanan bahan, penerapan kebijakan untuk tidak menyediakan safety stock
bahan, bahan yang belum dikirimkan oleh supplier, serta jumlah pekerja yang
berpengaruh terhadap beban kerja. Di akhir penelitian disimpulkan bahwa
alternatif perbaikan yang diajukan adalah dengan melakukan penelitian untuk
pembuatan SOP yang lebih terinci, juga mengadakan pelatihan sesuai dengan
SOP baru tersebut. Berdasarkan hasil perhitungan value analysis, dengan
tambahan biaya 3,6% dari proses produksi eksisting untuk penerappenerapan alternatif
tersebut dapat memperbaiki performansi hingga 31,75% lebih baik. =========== Based on interviews with the managers, there are several problems at PT. X such
as rework at drying process, idle time of either workers or machines, and material
handling difficulties due to material placement that not well organized, which
indicates that there are problems that need to be analyzed and improved. To solve
these problems, this research implements Lean approach to identify non-value
adding activities, critical waste, with its critical root causes, and recommend
alternative through value analysis that can improve production process
performance with effective and efficient cost. Through this research, known that
5.56% of production lead time is used for value adding activities, and top 3
critical waste that prioritized among 7 waste in Lean approach are Delay &
Waiting with weights of 22.6%, Unnecessary Motion 20.2%, and Inappropriate
Processing 19%. Furthermore the critical root cause are the expertise and
experience of workers, workers condition that is not optimal at work, material
treatment facilities during shipment and storage, the material safety stock
availibility, material that has not delivered yet by suppliers, and number of
workers that affect the workload. At the end of this research concluded that the
alternative measures recommended to be applied in the production process of
colored plastic pellets of PT. X is provide research to make detailed SOP of
production process activities, also training for workers that corresponding with
these new SOP. Based on the results of value analysis, known that with an
additional charge of 3,6% of existing production process cost for the
implementation of these alternatives can improve performance up to 31.75%
better.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.155 2 Sar i 2509100086 |
| Uncontrolled Keywords: | Lean Manufacturing, 7 Waste, Big Picture Mapping, Root-Cause Analysis, FMEA, Value Analysis, Rank Sum. |
| Subjects: | T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) T Technology > TS Manufactures > TS167 Costs, Industrial |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | - Davi Wah |
| Date Deposited: | 14 Mar 2019 01:54 |
| Last Modified: | 14 Mar 2019 02:02 |
| URI: | http://repository.its.ac.id/id/eprint/62489 |
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