Upaya Pengurangan Pemborosan Pada Proses Produksi Dresser Di Pt X Menggunakan Pendekatan Lean Manufacturing

Priswanto, Anisa Dwi (2021) Upaya Pengurangan Pemborosan Pada Proses Produksi Dresser Di Pt X Menggunakan Pendekatan Lean Manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT X merupakan perusahaan yang bergerak di industri manufaktur furnitur. Produk yang dihasilkan dibedakan menjadi 2 kategori jenis, yaitu knock down dan fully assembled. Perusahaan mendapatkan masalah komplain terbanyak dari produk knock down, yaitu sebesar 40-50 komplain setiap bulan. Hasil wawancara dengan pihak Quality Control (QC) ternyata kerap terjadi 3R (return, reject, repair). Hal tersebut mengindikasikan adanya pemborosan (waste) seperti operator yang kurang teliti dalam bekerja sehingga menghasilkan produk defect, lead time semakin panjang akibat rework, menunggu produk yang di-return ke departemen sebelumnya akibat terjadi kesalahan. Oleh karena itu, penelitian ini bertujuan untuk mengidentifikasi dan mengurangi aktivitas yang tidak bernilai tambah dengan menggunakan konsep lean manufacturing. Penelitian ini bermula dari pembuatan pemetaan aliran nilai menggunakan Value Stream Mapping (VSM) lalu dilanjutkan dengan melakukan pemetaan seluruh aktivitas pada proses produksi menggunakan metode Process Activity Mapping (PAM). Dengan menggunakan Gemba Shikumi, ditemukan adanya tiga (3) waste kritis antara lain melakukan penataan bagian assembling permukaan, bagian packing, dan bagian pendempulan. Lalu setelah dilakukan analisis akar penyebab menggunakan 5 whys, ditemukan akar penyebab waste kritis antara lain tidak adanya workload analysis, tidak adanya instruksi kerja, tempat kerja tidak terorganisir dengan baik, beberapa proses dilakukan manual, dan tidak adanya kebijakan sebelum melakukan perjanjian kontrak. Rekomendasi perbaikan disusun berdasarkan 5 akar penyebab tersebut, dan pada modified lean matrix yang telah mempertimbangkan tingkat efektivitas dan tingkat kesulitan rekomendasi, didapatkan hasil bahwa rekomendasi penyusunan instruksi kerja menduduki urutan peringkat pertama.
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PT X is a furniture manufacturing industry. The products produced are
divided into 2 types, they are knock down and fully assembled. The most
complaints are on knock down products, which are 40-50 complaints every month.
Based on Quality Control (QC) staff explanation, it often occured 3R (return, reject,
repair) in the production process. This indicates that there are waste, such as
operators who are less careful in their work resulting in defective products, longer
lead times due to rework, and waiting products which returned to the previous
department due to defects. Therefore, this study aims to reduce non-value-added
activities using the lean manufacturing concept. This research begins with making
value flow mapping using Value Stream Mapping (VSM) and then proceeding with
Process Activity Mapping (PAM) method to be able to classify all types of
activities. By using Gemba Shikumi, three (3) critical wastes were found, including
structuring the surface assembling, packing, and caulking parts. Followed by root
cause analysis using 5 whys, the root causes of critical wastes are there is no
workload analysis, there is no work instructions, the place is not well organized,
some processes are done manually, and there is no policy before entering into a
contract agreement. Recommendations for improvement are arranged based on
those 5 root causes, and on the modified lean matrix which has considered the level
of effectiveness and difficulty of the recommendations, it is found that the
recommendations for creating work instructions are ranked first.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	Industri Manufaktur Furnitur, Lean Manufacturing, Waste, Gemba Shikumi, 5 Whys, Lean Assessment Matrix, Furniture Manufacturing Industry, Lean Manufacturing, Waste, Gemba Shikumi, 5 Whys, Lean Assesment Matrix.
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Anisa Dwi Priswanto
Date Deposited:	18 Aug 2021 14:33
Last Modified:	18 Aug 2021 14:33
URI:	http://repository.its.ac.id/id/eprint/87251

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