Strategi Perbaikan Proses Produksi Velg Tipe 7.50V Menggunakan Pendekatan Lean Manufacturing (Studi Kasus : Perusahaan Velg Gresik)

Qomariyah, Siti (2019) Strategi Perbaikan Proses Produksi Velg Tipe 7.50V Menggunakan Pendekatan Lean Manufacturing (Studi Kasus : Perusahaan Velg Gresik). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Perusahaan velg Gresik memproduksi heavy-duty steel wheel rim dengan kapasitas 600.000 unit tiap tahun. Proses produksi ditunjang lima lini produksi. Meskipun telah menerapkan Lean Manufacturing, namun berdasarkan data historis masih ditemukan waste. Lini produksi side ring menyumbangkan 51% defect pada tahun 2018. Waste lainnya juga muncul yang mengakibatkan terganggunya proses produksi. Penelitian ini bertujuan untuk mereduksi terjadinya waste dan menghasilkan strategi perbaikan. Metode yang digunakan adalah Lean Manufacturing yang diawali dengan identifikasi proses produksi menggunakan Value Stream Mapping. Penentuan tiga waste terkritis menggunakan opportunity cost dan diagram pareto. Akar penyebab waste dianalisis menggunakan Root Cause Analysis dan akar penyebab terkritis dianalisis menggunakan Failure Mode and Effect Analysis dengan melihat nilai RPN>100. Dari hasil FMEA diberikan tiga usulan perbaikan, yaitu penambahan operator maintenance sekaligus penerapan aplikasi reminder/bel untuk pelaksanaan maintenance, pembentukan tim 5S, dan pembuatan database fasilitas mesin. Kemudian melakukan analisis penggantian perspektif keusangan untuk mengetahui kelayakan mesin produksi eksisting. Pemilihan alternatif usulan perbaikan menggunakan Value Engineering, dimana kombinasi yang terpilih adalah alternatif 1, 2, dan 3 dengan value sebesar 1,53 dan biaya alternatif sebesar Rp 645.144.744,-. Alternatif terpilih selanjutnya dianalisis dengan perspektif keterlibatan antar departemen agar dapat meningkatkan performansi pada proses produksi velg secara keseluruhan.
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Company velg Gresik produces heavy-duty steel wheel rims with a capacity of 600,000 units every year. The production process is supported by five production lines. Although the company has implemented Lean Manufacturing, historical data shows that waste is still found. The side ring production line contributed 51% of defects in 2018. Other wastes also appeared, resulting in disruptions to the production process. This research aims to reduce the occurrence of waste and produce improvement strategies. The method used is Lean Manufacturing, beginning with the identification of the production process using Value Stream Mapping. The determination of the three critical wastes uses opportunity cost and a Pareto diagram. The root cause of waste is analyzed using Root Cause Analysis, and the root of the most critical cause is analyzed using Failure Mode and Effect Analysis by examining RPN values above 100. From the results of the FMEA, three improvement proposals were generated, namely adding maintenance operators and implementing a reminder/bell system for maintenance, establishing a 5S team, and establishing a machine facility maintenance database. A change-of-perspective obsolescence analysis was then conducted to determine the feasibility of the existing production machines. The selection of alternative improvement proposals uses Value Engineering, where the selected combination is alternatives 1, 2, and 3, with a value of 1.53 and an alternative cost of Rp. 635,644,444. The chosen alternative is then analyzed from the perspective of involvement between departments in order to improve performance across the overall wheel production process.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Failure Mode and Effect Analysis, Lean Manufacturing, Opportunity Cost, Root Cause Analysis, Value Stream Mapping
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures T Technology > TS Manufactures > TS167 Costs, Industrial
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Siti Qomariyah
Date Deposited:	21 Jul 2026 08:56
Last Modified:	21 Jul 2026 08:56
URI:	http://repository.its.ac.id/id/eprint/65452

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