Nugroho, Joshua Triputro (2016) Reduksi Waste Pada Proses Produksi Pasta Gigi Pt. X Dengan Konsep Lean Production Dan Benefit Cost Ratio. Undergraduate thesis, Institut Teknologi Sepuluh Nopember Surabaya.
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Abstract
PT.X merupakan salah satu perusahaan Fast Moving Consumer Goods
(FMCG) terkemuka di Indonesia yang berdiri sejak tahun 1933. Beberapa produk
unggulan PT. X adalah Pasta Gigi P dan Pasta Gigi CU. Hal ini dibuktikan dengan
besarnya jumlah rata-rata market share kedua produk ini, yaitu 85,56% selama
tahun 2008-2010. Namun, terdapat permasalahan pada proses produksi kedua
produk tersebut. Hal ini dibuktikan dengan tidak tercapainya target output rate
beberapa varian dari kedua produk tersebut selama bulan Januari hingga Maret
2016, yaitu dengan rata-rata 93,53% dari target perusahaan 96%. Hal ini terjadi
karena diindikasikan adanya pemborosan (waste) pada lantai produksi seperti
hasil pasta gigi yang defect dan adanya bottleneck pada proses pengemasan. Oleh
karena itu, diperlukan penerapan konsep lean production untuk mereduksi waste
tersebut. Penelitian ini dilakukan pada varian produk Pasta Gigi P White dan
Pasta Gigi CU Green karena tingginya permintaan pada 2 jenis produk ini.
Penelitian ini dimulai dengan mengidentifikasi waste kritis menggunakan metode
Value Stream Mapping (VSM) dan Borda Count Method (BCM). Waste kritis
yang didapatkan yaitu waste defect, waiting, dan inventory. Setelah didapatkan
waste kritis, selanjutnya dilakukan analisis akar penyebab permasalahan waste
kritis tersebut dengan Root Cause Analysis (RCA) menggunakan teknik 5 Why’s
dan Failure Mode and Effect Analysis (FMEA) untuk mengetahui root cause
dengan prioritas tertinggi. Setelah didapatkan root cause dengan prioritas
tertinggi, diberikan rekomendasi perbaikan dan dilakukan analisis Benefit Cost
Ratio (BCR). Berdasarkan hasil analisis dan perhitungan, didapatkan 3
rekomendasi perbaikan yaitu pembuatan standard operational procedure (SOP)
yang melibatkan proses kalibrasi dan pembersihan dengan nilai BCR sebesar 1,44
untuk waste defect, pengadaan safety stock untuk packaging material dengan nilai
BCR sebesar 1,15 untuk waste waiting, dan pengadaan pallet rack untuk pallet
hasil racikan pada area processing dengan nilai BCR sebesar 1,67 untuk waste
inventory. Karena ketiga rekomendasi perbaikan ini bernilai lebih dari 1, maka
seluruh rekomendasi perbaikan layak dilakukan. Dengan rekomendasi ini,
diharapkan output rate produksi dapat meningkat dan mencapai target perusahaan.
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PT. X is one of the top Fast Moving Consumer Goods (FMCG)
manufacturer in Indonesia that established since 1933. Some of the superior
products in PT. X are P White Toothpaste and CU Green Toothpaste. It is proven
by the large number of market share from these two products with an average
85.56% during 2008-2010. However, there are some problems in the production
process of these products. It is proven by several variants from these two products
were not achieving the company’s output rate target during January to March
2016, which is only having an average 93.53% out of 96% from the company's
target. This problem occurs due to the indication of waste on the production floor
such as toothpase defect and bottleneck at the packing line. Therefore, it needs to
apply the concept of lean production to reduce waste. Research was conducted on
the product variant P White Toothpaste and CU Green Toothpaste because of the
high demand on these two types of products. The research started by identifying
critical waste using Value Stream Mapping (VSM) and the Borda Count Method
(BCM). Earned critical waste are defect, waiting, and inventory. After knowing
the critical waste, Root Cause Analysis (RCA) is conducted by using 5 Why's
technique and Failure Mode and Effect Analysis (FMEA) to determine the root
cause with the highest priority. After obtaining the root cause with highest
priority, improvement recommendations are given and analyzed by using Benefit
Cost Ratio (BCR). Based on the analysis and calculation, it is obtained three
recommendations for improvement, such as Standard Operational Procedure
(SOP) which involves the process of calibration and cleaning with BCR value
1.44 for the defect waste, safety stock for packaging material with BCR value
1.15 for waiting waste, and procurement of pallet rack for pallet concoction in the
processing area with BCR value 1.67 for the inventory waste. As BCR value of
these given recommendations are more than 1, then all recommendations are
feasible to be done. With this recommendations, the production output rate will be
expected to increase and reach the company’s target.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.5 Nug r |
| Uncontrolled Keywords: | Benefit Cost Ratio, Borda Count Method, Failure Mode and Effect Analysis, Lean Production, Root Cause Analysis, VSM, Waste |
| 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: | 03 Jan 2020 06:32 |
| Last Modified: | 03 Jan 2020 06:32 |
| URI: | http://repository.its.ac.id/id/eprint/72516 |
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