Analysis of Production Process of Electronic Transformer by Lean Six Sigma and TRIZ

Zaifar, Adritho (2023) Analysis of Production Process of Electronic Transformer by Lean Six Sigma and TRIZ. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT X adalah salah satu produsen dan distributor utama trafo elektronik di Indonesia. Perusahaan berusaha untuk peningkatan kuantitas dan kualitas yang diminta oleh pelanggan. Pada saat yang sama, perusahaan ingin meminimalkan aktivitas yang tidak bernilai tambah dalam proses produksi. Tujuan dari penelitian ini adalah untuk meningkatkan efisiensi dan kualitas trafo elektronik yang dihasilkan. Penelitian ini menggunakan Lean Six Sigma dan Root Cause Analysis untuk mengidentifikasi pemborosan dalam proses produksi yang menyebabkan waktu tunggu yang lama dan standar kualitas yang lebih rendah. Metodologi TRIZ akan digunakan untuk mendukung upaya perbaikan proses apabila proses perbaikan yang dihasilkan dari metode Lean Six Sigma menghasilkan kontradiksi. Jenis data yang akan digunakan adalah data alur produksi trafo elektronik dari awal sampai akhir serta data diskusi kelompok yang digunakan. Hasil penelitian menemukan bahwa jika PT. X mengeliminasi aktivitas yang tidak bernilai tambah melalui otomatisasi, investasi yang dilakukan perusahaan pada teknologi tersebut dianggap menguntungkan karena hasil perhitungan NPV adalah positif Rp. 43.181.818. Hasil otomatisasi ini juga akan memungkinkan PT. X untuk mengurangi jumlah tenaga kerjanya yang menghasilkan penghematan biaya sekitar 54% dari biaya tenaga kerjanya dimana jika dikonversi ke dalam nilai uang menjadi Rp. 68.255.748 tabungan finansial.
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PT X is one of Indonesia's main manufacturers and distributors of electronic transformers. The company has struggled to keep up with the increased quantity and quality demanded by customers. At the same time, the company wants to minimize non-value-added activities in the production process. This research aims to identify the main factors of the transformer production process to improve the efficiency and quality of the electronic transformers produced. This research uses Lean Six Sigma and Cause Analysis to identify waste in the production process that causes long lead times and lower quality standards. The TRIZ methodology will support process improvement efforts if the improvement resulting from the Lean Six Sigma method produces contradictions. The data that will be used is data on the production flow of electronic transformers from start to finish and data on group discussions. The result of the studies found that if PT. X eliminates non-value-added activities through automation, the investment that the company made in these technologies is deemed profitable as the NPV calculation result is a positive Rp. 43,181,818. The result of this automation will also enable PT. X to reduce the number of its labour which resulting a cost saving of around 54% of its labour cost in which if converted into monetary value will be Rp. 68,255,748 in financial savings.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Root Cause Analysis, TRIZ, Focus Group Discussion (FGD), Lean Six Sigma, Productivity, Quality Improvement
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment. T Technology > T Technology (General) > T56.8 Project Management T Technology > T Technology (General) > T58.8 Productivity. Efficiency
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Adritho Zaifar
Date Deposited:	04 May 2023 05:40
Last Modified:	04 May 2023 05:40
URI:	http://repository.its.ac.id/id/eprint/97896

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