Nurfi, Elfaruri (2016) Implementasi Lean Manufacturing Dalam Mereduksi Waste Pada Sistem Produksi Karpet Mobil Di Pt. Classic Automotive Manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember Surabaya.
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Abstract
PT. Classic Automotive Manufacturing (PT. CAM) merupakan salah satu
perusahaan penghasil karpet mobil di Surabaya. Produk yang dibuat oleh PT.CAM
bersifat Make to Order. PT. CAM menjadi salah satu pemasok karpet mobil di tujuh
distributor aksesoris yang berlokasi di Jepang. Prosentase pengiriman terbesar ialah
pada perusahaan Faltec America (FA) yang merupakan distributor aksesoris mobil
Nissan Juke. Dalam menjalankan sistem produksinya PT.CAM mengalami
beberapa kendala diantaranya tidak tercapainya jumlah perencanaan produksi pada
bulan Oktober 2015 hingga Februari 2016, adanya breakdown mesin yang
mengakibatkan pekerja harus lembur dan adanya defect produk yang
mengakibatkan kerugian biaya yang cukup tinggi. Dalam penelitian ini kendala
tersebut diselesaikan menggunakan pendekatan lean manufacturing Langkahlangkah
penyelesaian dimulai dari mendeskripsikan proses produksi dengan
menggunakan OPC dan VSM. Selanjutnya identifikasi waste kritis dengan metode
Borda dan ditemukan tiga waste kritis yaitu waiting, defect dan motion. Dari ketiga
waste tersebut kemudian diidentifikasi akar permasalahannya dengan RCA dan
menentukan prioritas akar permasalahan dengan FMEA. Solusi perbaikan yang
diusulkan antara lain menyeimbangkan penugasan dari lini penjahitan hingga
packaging dengan menggunakan metode line balancing, modifikasi desain plat
pada slide mesin trimming, membuat form pemeliharaan mesin extruder, dan
menambahkan pengecekan ulang set up mesin extruder ke dalam SOP. Masingmasing
alternatif solusi perbaikan dianalisis dengan benefit cost ratio. Berdasarkan
perhitungan BCR keempat alternatif perbaikan memiliki ratio > 1 yang berarti
solusi tersebut layak diterapkan di perusahaan.
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PT. Classic Automotive Manufacturing (PT. CAM) is one of car mats manufacturer
in Surabaya. Their production process based on customer order. PT. CAM is the
supplier of the car mats in seven distributors of automobile accessories in Japan.
Their products are mostly shipped to Faltec America (FA) which is an automobile
accessories distributor of Nissan Juke. In carrying out its production system
PT.CAM having some problems such as fail to achieve the number of production
planning in October 2015 until February 2016, breakdown machine which affect
overtime works, and defects of products which affect high losses costs. That
problems can be solved by using lean manufacturing approach. This research is
conducted by describing the production process using OPC and VSM. The next step
is identificating the critical waste with Borda method. Waiting, defects and motion
are identified as critical waste. That critical waste will be identified the root causes
by using RCA and the priority of root causes by using FMEA. The alternatives
solutions that to be proposed are balancing the task from sewing lines until
packaging lines, modificating the plates’s design of trimming machine’s slide,
making maintenance form for extruder machine, and adding operational standard
procedure (re-checking set up for extruder machine). The final step is calculating
the cost of each alternative solution by using benefit cost ratio. Based on BCR
results, all the alternative solutions have ratio>1, it means that the solutions is
feasible.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.5 Nur i |
| Uncontrolled Keywords: | Benefit Cost Ratio, Lean manufacturing, Line balancing, OPC, VSM |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | EKO BUDI RAHARJO |
| Date Deposited: | 02 Dec 2019 02:00 |
| Last Modified: | 02 Dec 2019 02:00 |
| URI: | http://repository.its.ac.id/id/eprint/72124 |
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