Perbaikan Sistem Produksi Kemasan Body Lotion dengan Pendekatan Lean Manufacturing pada PT. Z

Hasian, Arnold (2019) Perbaikan Sistem Produksi Kemasan Body Lotion dengan Pendekatan Lean Manufacturing pada PT. Z. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. Z merupakan perusahaan yang bergerak dibidang produksi kemasan plastik, yang telah berdiri sejak tahun 1969 di Jakarta, dan saat ini sudah memiliki tujuh pabrik yang berada di Indonesia dan China. PT. Z memproduksi berbagai jenis kemasan berbahan platik, dan salah satunya adalah produk kemasan body lotion yang menjadi objek amatan pada penelitian ini. Produk kemasan body lotion menjadi objek pilihan pada pengamatan ini karena memiliki permasalahan yang cukup kompleks pada proses produksinya terbukti dengan terjadinya keterlambatan produk yang sangat sering hingga mencapai 48% pada bulan Desember 2018. Permasalahan pada proses produksi kemasan body lotion coba diselesaikan dengan pendekatan lean manufacturing dan bantuan metode lean assessment matrix yang diadopsi dari penggabungan House of Risk dan Waste Relationship Matrix. Berdasarkan hasil pengamatan pada proses produksi, ditemukan tujuh jenis pemborosan yang terjadi yaitu defects, overproduction, overprocessing, waiting, motion, transportation dan inventory. Proses pengamatan yang dilakukan pada proses produksi kemasan body lotion menggunakan pendekatan Value Stream Mapping (VSM) dan Process Activity Mapping (PAM) untuk melihat rincian aktivitas yang berjalan pada proses produksi kemasan body lotion. Setelah ditemukan pemborosan pada proses produksi, dilakukan proses pencarian akar masalah dengan menggunakan metode 5 whys. Kemudian dilakukan proses identifikasi hubungan antara jenis pemborosan menggunakan metode Waste Relationship Matrix (WRM) untuk melihat jenis pemborosan yang paling mempengaruhi jenis pemborosan lainnya. Hasil dari WRM dan akar masalah akan menjadi input bagi lean matrix 1 untuk selanjutnya dapat dicari pemborosan kritis berdasarkan nilai Aggregate Cause Value yang didapatkan dari nilai severity pemborosan, occurence akar pemborosan dan waste type weight untuk menghitung Aggregate Waste Number. Hasil dari lean matrix 1 berupa peringkat pemborosan kritis yang menjadi prioritas untuk diselesaikan terlebih dahulu. Pada penelitian ini diambil 3 peringkat teratas untuk dicari rekomendasi perbaikannya menggunakan lean matrix 2. Proses formulasi rekomendasi perbaikan pada lean matrix 2 mempertimbangkan nilai effectiveness dari penerapan rekomendasi, impact value, serta derajat kesulitan penerapan rekomendasi perbaikan. Dari hasil perhitungan lean matrix 2 didapatkan rekomendasi perbaikan peringkat 1 adalah rekomendasi perbaikan modifikasi/penggantian komponen mesin conveyor.
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PT. Z is a company engaged in the production of plastic packaging, which has been established since 1969 in Jakarta, and currently has seven factories located in Indonesia and China. PT. Z manufactures various types of packaging made from plastic, and one of them is the body lotion packaging product which is the object of observation in this study. Body lotion packaging products are the object of choice in this observation because it has quite complex problems in the production process as evidenced by the frequent product delays up to 48% in December 2018. Problems with the production process of body lotion packaging can be solved with lean manufacturing approaches and the lean assessment matrix method adopted from the merger of the House of Risk and the Waste Relationship Matrix that was developed by Rawabdeh. Based on the results of observations in the production process, the writer found seven types of waste that occur, namely defects, overproduction, overprocessing, waiting, motion, transportation and inventory. The observation process carried out in the production process of body lotion packaging using the Value Stream Mapping (VSM) and Process Activity Mapping (PAM) approaches to see details of the activities that run in the production process of body lotion package. After waste was founded in the production process, the search process for the root of the problem is carried out using 5 whys methods. Then the process of identifying the relationship between types of waste was carried out using the Waste Relationship Matrix (WRM) method to see the type of waste that most affected other types of waste. The results of WRM and the root of the problem will be input for lean matrix 1, which next the critical waste can be searched using the value of Aggregate Cause Value, which can be occured by using severity level of waste, Occurence level of root source of waste, and Waste Type Weight to calculate the Aggregate Waste Number. The results of lean matrix 1 in the form of critical wastage ranks are a priority to be resolved first. In this research, the top 3 rankings were taken to find recommendations for improvement using lean matrix 2. The process of recommendations for formulation of improvements in lean matrix 2 considers the effectiveness of the recommendations, impact values, and the degree of difficulty in implementing recommendations for improvement. From the results of the calculation of lean matrix 2, the recommendation for improvement is to the modificate / replace the conveyor engine components.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Waste, Lean Manufacturing, VSM, PAM, Waste Relationship Matrix, Lean Assessment Model
Subjects:	T Technology > TS Manufactures
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Arnold Hasian
Date Deposited:	21 Jul 2026 08:03
Last Modified:	21 Jul 2026 08:03
URI:	http://repository.its.ac.id/id/eprint/65780

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