Andona, Afril (2023) Analisis Waste Dengan Menggunakan Metode Value Stream Mapping dan Failure Mode & Effect Analysis : Studi Kasus Perusahaan Rokok Kadar Tar Tinggi PT XYZ. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Setiap perusahaan memiliki target produksi yang harus di capai selama periode tertentu, indikator kunci keberhasilan yang digunakan oleh sebuah industri rokok dalam mencapai target produksi adalah production lost yang rendah. PT XYZ sebuah perusahaan penghasil rokok kadar tar tinggi mempunyai permasalahan production lost pack yang tinggi sebesar 993.531.985 pack di tahun 2021. Berdasarkan data output produksi rokok kadar tar tinggi diindikasikan adanya defect produk dan delay produk. Berdasarkan latar belakang hal tersebut maka, penelitian ini bertujuan untuk mengeleminasi dan mereduksi waste perusahaan rokok kadar tar tinggi PT XYZ. Analisa penelitian ini dilakukan dengan identifikasi proses produksi rokok menggunakan Value Stream Mapping, Process Activity Mapping, kemudian mencari waste kritis dengan Borda Count Method, selanjutnya dilakukan analisis akar masalah dengan Root Cause Analysis 5Why’s. Berdasarkan Failure Mode and Effect Analysis diketahui akar penyebab waste tertinggi adalah berat rokok tidak sesuai spesifikasi, printing rokok hilang atau geser, tipping paper rokok terlipat serta lamanya proses start up. Perbaikan yang dilakukan yaitu penerapan metode Poka Yoke dengan penggantian trimmer disk, instalasi sensor high speed camera dan membagi task list cleaning, mampu menurunkan production lost pack PT XYZ sebesar 4.3% di tahun 2022.
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Every company has a production target that must be achieved during a certain period. The key indicators used by cigarette industry in achieving production targets is a low production loss. The XYZ is a company that produces high tar cigarettes that has a high production loss pack problem up to 993.531.985 packs in 2021. According to the output data of high tar cigarette production it is indicated that there are any defects and delays in the products. Based on that background, the aim of this research is to eliminate and reduce the waste of high tar cigarette that produced by XYZ company. The initial analysis of this research was carried out by identifying the production process using Value Stream Mapping, Process Activity Mapping, the next process is looking for critical waste using the Borda Count Method, then analyzing the root of the problem using Root Cause Analysis 5Why's. By using Failure Mode and Effect Analysis it is found that the root cause of the highest waste is the cigarettes weight out of tolerant, lost cigarette printing or shifted, tipping turn back and machine start-up time. The proposed improvement are by implementing the Poka Yoke method, including replacing the trimmer disk, installing high speed camera sensor and dividing the cleaning task list, which can reduce XYZ company production lost pack up to 4.3% in 2022.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Waste, Value Stream Mapping, Process Activity Mapping, Borda Count Method, Root Couse Analysis, Failure Mode and Effect Analysis |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management H Social Sciences > HD Industries. Land use. Labor > HD56.25 Industrial efficiency--Measurement. Industrial productivity--Measurement. H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Afril Andona |
| Date Deposited: | 28 Jan 2023 20:07 |
| Last Modified: | 28 Jan 2023 20:07 |
| URI: | http://repository.its.ac.id/id/eprint/95755 |
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