Aghda, Bachtiar Rosihan (2020) Pemodelan Integrasi Proses Handling pupuk in-bag dan kebutuhan forklift untuk mereduksi waste di Gudang Penjualan PT Petrokimia Gresik. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Pupuk merupakan komoditi yang harus dijaga ketersediannya dan harus disalurkan tepat waktu agar tidak terjadi kelangkaan pupuk. PT. Petrokimia Gresik merupakan salah satu perusahaan produsen pupuk yang memiliki tugas memproduksi pupuk dan bahan kimia lainnnya serta menjualnya kepada petani sesuai dengan alokasi kebutuhan pupuk yang ditetapkan pemerintah. Proses penyaluran dan distribusi yang baik kepada petani membutuhkan perencanaan terhadap sarana dan prasarana yang baik, salah satunya di Gudang Penjualan PT. Petrokimia Gresik dalam proses handling pupuk in-bag. Proses handling pupuk tersebut terdiri dari kegiatan pengantongan di area pengantongan oleh tenaga borong, kegiatan handling dan penataan pupuk oleh forklift di area penataan serta kegiatan muat pupuk menggunakan tenaga borong dan truk.
Dalam proses handling pupuk in-bag diketahui terdapat proses tunggu/idle time forklift yang mengakibatkan forklift memiliki workload yang tidak seimbang, proses idle forklift tersebut mengindikasikan forklift yang terlalu banyak sehingga mengakibatkan pemborosan biaya karena forklift menggunakan sistem sewa. Penelitian ini bertujuan untuk mengidentifikasi waste yang terjadi di proses handling pupuk in-bag menggunakan metode Value Stream Mapping (VSM) dan menganalisa penyebabnya dengan menggunakan metode Root Cause Analysys (RCA) serta melakukan validasi hasil perbaikan menggunakan simulasi arena 14.0.
Hasil kuesioner didapatkan, waste disebabkan karena waiting sebesar 28.2% dan unnecessary motion sebesar 22.7%. Dengan PAM tools menunjukkan waktu siklus pengiriman pupuk sebesar 9030 detik dengan Value Added Activity sebesar 66%. Rekomendasi sesuai VSM yaitu menambahkan tenaga pada proses penataan dan pemuatan sehingga aktifitas value added meningkat 75.8% dengan waktu siklus 7733 detik. Hasil validasi Arena 14.0 menunjukkan forklift-3 bisa dihilangkan dan aktifitasnya dapat digabungkan dengan forklift lain kemudian memindahkan tenaga penjahitan ke pembongkaran serta menggabungkan aktifitas menjahit kepada tenaga pengisian sehingga mengurangi waktu tunggu truk dari 7.9 jam menjadi 2.9 jam. Dengan menghilangkan 1 forklift di masing-masing gudang perusahaan dapat menghemat biaya sewa sebesar Rp. 4.772.376.000,-/tahun.
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Fertilizer is a commodity that must be maintained and must be distributed on time to avoid fertilizer scarcity. PT. Petrokimia Gresik is a fertilizer manufacturing company that has the task of producing fertilizers and other chemicals and selling them to farmers in accordance with the allocation of fertilizer requirements set by the government. The process of good distribution and distribution to farmers requires planning of good facilities and infrastructure, one of which is at PT. Petrokimia Gresik in the process of handling in-bag fertilizers. The fertilizer handling process consists of bagging activities in the bagging area by the labor force, handling and fertilizer arrangement activities by the forklift in the arrangement area and fertilizer loading activities using labor force and trucks.
In the process of handling in-bag fertilizer, it is known that there is a waiting / idle time forklift process which results in the forklift having an unbalanced workload, the forklift idle process indicates too many forklifts, resulting in waste of costs because the forklift uses the rental system. This study aims to identify the waste that occurs in the in-bag fertilizer handling process using the Value Stream Mapping (VSM) method and analyze the causes using the Root Cause Analysys (RCA) method and validating the results of improvement using arena simulation 14.0.
Through the questionnaire, waste caused by waiting 28.2% and unnecessary motion 22.7%. With PAM tools, the fertilizer delivery cycle time is 9030 seconds with a value added activity of 66%. Recommendations using VSM are adding the staple and loading labor so that value added activities increase by 75.8% with 7733 seconds cycle time. The results simulation show that forklift-3 can be removed and its activities can be combined, then transferring the sewing labor to the loading process and combining sewing activities in the bagging activities thereby reducing the truck's waiting time from 7.9 hours to 2.9 hours. By removing 1 forklift, the company can save rental costs of Rp. 4,772,376,000 / year.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | fertilizer handling process, forklift idle time, unbalanced workload, Value Stream Mapping, waste, simulation, rental cost. |
| Subjects: | Q Science > Q Science (General) T Technology > TS Manufactures > TS155 Production control. Production planning. Production management |
| Divisions: | Faculty of Creative Design and Digital Business (CREABIZ) > Technology Management |
| Depositing User: | BACHTIAR ROSIHAN AGHDA |
| Date Deposited: | 14 Aug 2020 05:16 |
| Last Modified: | 10 Jun 2023 14:36 |
| URI: | http://repository.its.ac.id/id/eprint/78104 |
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