Minimasi Waste (Pemborosan) Pada Proses Produksi Pupuk Organik (Petroganik) Di Pt Petrokimia Gresik Menggunakan Pendekatan Lean Manufacturing

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 > (S1) Undergraduate Theses
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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