Purnasari, Indah (2016) Minimasi Waste (Pemborosan) Pada Proses Produksi Pupuk Organik (Petroganik) Di Pt Petrokimia Gresik Menggunakan Pendekatan Lean Manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Petroganik merupakan salah satu jenis pupuk organik yang dihasilkan
oleh PT Petrokimia Gresik dengan bahan baku utama kotoran hewan. Berdasarkan
data dari Kementerian Pertanian, permintaan petroganik diproyeksikan meningkat
sebesar 12% hingga tahun 2025. Tahun 2015, PT Petrokimia Gresik mendapatkan
target produksi petroganik sebesar 766.600 ton dengan hasil produksi 740.073
ton. Hasil ini didapatkan dari rekapitulasi data oleh 139 mitra yang memproduksi
petroganik PT Petrokimia Gresik, salah satunya milik PT Petrokimia Gresik.
Tahun 2015, pabrik petroganik milik PT Petrokimia Gresik mendapatkan alokasi
sebesar 2150 ton dengan realiasi produksi 1650,6 ton. Hal ini dikarenakan
kapasitas mesin pabrik belum mampu memenuhi produksi sesuai target yang
ditentukan. Dari data historis perusahaan dan pengamatan langsung di lapangan
menunjukkan adanya beberapa waste di lantai produksi. Oleh karena itu, penulis
melakukan penelitian menggunakan metode lean manufacturing agar dapat
mereduksi waste di produksi petroganik. Penelitian dimulai dengan menganalisis
proses sepanjang value stream menggunakan pendekatan big picture mapping.
Kemudian dilakukan identifikasi aktivitas value added, non value added, dan
necessary but non value added. Hasil tersebut berturut – turut adalah 29%, 34%,
dan 37%. Waste kritis yang terjadi di produksi petroganik adalah waiting, defect,
dan inventori. Setelah identifikasi waste, langkah selanjutnya adalah pembuatan
RCA dan FMEA untuk mengetahui root cause penyebab waste dan alternatif
perbaikan. Pemilihan alternatif terbaik dilakukan dengan mempertimbangkan
performansi dan cost menggunakan metode value engineering. Hasil tersebut
menunjukkan bahwa alternatif terbaik adalah peningkatan kinerja operator melalui
pembuatan form hasil kerja operator, form kesesuaian pekerjaan operator dengan
SOP, dan form aktivitas cleaning di lantai produksi.
===========================================
Petroganik is one type of organic fertilizers that is produced by PT
Petrokimia Gresik with the main raw is dung. Based on data from the Ministry of
Agriculture, the demand is projected to increase by 12% in 2025. In 2015, PT
PKG allocates petroganik production of 766 600 tonnes to 740 073 tonnes. These
results were obtained from data summary by 139 partners who produce
petroganik, one of them is belonging to PT PKG. In 2015, the factory owned by
PT PKG petroganik get an allocation of 2150 tonnes but only 1650.6 tonnes of
production which can release. This condition as the results of plant capacity
machinery has been unabled to handle the production target. From the historical
data and the company's direct observation reveal a number of waste on the
production floor. Hence, the author conducted lean manufacturing research in
order to reduce waste in petroganik production. The research commenced by
analyzing the process along the value stream using big picture mapping. After
that, value added, non-value added and necessary but non-value added activity
will be identified. The results respectively are 29%, 34%, and 37%. Critical waste
occurring in the petroganik production is waiting, defect, and inventory. The next
step is making RCA and FMEA to determine the root cause of waste and
alternative of improvement will be defined. The best alternative will be defined by
considering it performance and cost, using value engineering method. The best
alternative is too increase operator performance through creation operator
performance form, performance suitability form with SOP and cleaning activity
on the production floor form.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.562 Pur m |
| Uncontrolled Keywords: | Big Picture Mapping (BPM), Failure Mode and Effect Analysis (FMEA), Lean Manufacturing, Root Cause Analysis (RCA) |
| Subjects: | Q Science > QA Mathematics > QA279.5 Bayesian statistical decision theory. |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | EKO BUDI RAHARJO |
| Date Deposited: | 01 Nov 2019 02:14 |
| Last Modified: | 01 Nov 2019 02:14 |
| URI: | http://repository.its.ac.id/id/eprint/71530 |
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