Analisis Waste Pada Proses Pengadaan Suku Cadang Dengan Pendekatan Lean (Studi Kasus Di Perusahaan Alat Berat)

Devi, Priesta Mayestika Karunia (2024) Analisis Waste Pada Proses Pengadaan Suku Cadang Dengan Pendekatan Lean (Studi Kasus Di Perusahaan Alat Berat). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pengadaan merupakan aspek krusial dalam menjalankan proses bisnis perusahaan distribusi alat berat yang mencakup pengadaan suku cadang. Selama satu tahun terakhir, dari 2036 part yang diadakan karena stockout, terjadi keterlambatan pada proses sales order ke delivery order (5%), delivery order ke transfer order open (16%), dan transfer order open ke transfer order confirmed (53%). Oleh karena itu, perlu dilakukan perbaikan yang bertujuan untuk mengidentifikasi permasalahan pada proses pengadaan dengan pendekatan lean dengan tools meliputi value stream mapping (VSM) dan process activity mapping (PAM) untuk memetakan proses pengadaan, lalu identifikasi waste kritis dilakukan dengan metode genba shikumi. Waste kritis yang didapatkan yaitu tidak ada memo resmi untuk reminder (S4), kurangnya tenaga kerja (S3), jam kerja hanya 1 shift (S5), tidak ada sistem pelaporan barang cacat (S2), tidak ada pengingat cut off time (S1), order yang tidak dapat diprediksi (S6), dan tidak ada formulir pengecekan stok rutin (S7). Waste kritis tersebut dianalisis dengan root cause analysis (RCA) dan diproses dalam failure mode and effect analysis (FMEA) untuk mengetahui nilai risk priority number (RPN) yang kemudian dilakukan fuzifikasi. Hasil RPN fuzzy digunakan untuk mengembangkan usulan perbaikan, dengan peringkat dari S4, S3, S5, S2, S1, S6, dan S7, masing-masing dengan nilai fuzzy 5.996; 5.866; 5.692; 5.324; 4.758; 4.717; dan 3.978. Prioritas alternatif perbaikan untuk S4 yaitu pengembangan dan distribusi memo resmi untuk reminder kepada customer; S3 dan S5 yaitu pengembangan formulir workload analysis untuk review kebutuhan karyawan dan penyesuaian jam kerja atau shift; S2 yaitu demand forecasting; S1 yaitu pengembangan SOP untuk reminder cut off time untuk proses transfer order; S6 yaitu pengembangan quality inspection form; dan S7 yaitu pengembangan formulir checklist stock audit.
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Procurement is a crucial aspect in running the business processes of a heavy equipment distribution company, which includes the procurement of spare parts. Over the past year, out of 2036 parts procured due to stockouts, delays occurred in the sales order to delivery order process (5%), the delivery order to transfer order open process (16%), and the transfer order open to transfer order confirmed process (53%). Therefore, improvements are needed to identify issues in the procurement process using a lean approach with tools including value stream mapping (VSM) and process activity mapping (PAM) to map the procurement process, followed by the identification of critical wastes using the genba shikumi method. The critical wastes identified are no official memo for reminders (S4), lack of manpower (S3), working hours only 1 shift (S5), no defective goods reporting system (S2), no cut off time reminder (S1), unpredictable orders (S6), and no routine stock check form (S7). These critical wastes were analyzed with root cause analysis (RCA) and processed in failure mode and effect analysis (FMEA) to determine the risk priority number (RPN), which was then fuzzified. The fuzzy RPN results were used to develop improvement suggestions, with rankings from S4, S3, S5, S2, S1, S6, and S7, each with fuzzy values of 5.996; 5.866; 5.692; 5.324; 4.758; 4.717; and 3.978, respectively. Improvement priorities for S4 include the development and distribution of official memos for reminders to customers; S3 and S5 include the development of workload analysis forms to review manpower needs and adjust working hours or shifts; S2 includes demand forecasting; S1 includes the development of SOPs for cut off time reminders for the transfer order process; S6 includes the development of quality inspection forms; and S7 includes the development of stock audit checklist forms.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Fuzzy, Genba Shikumi, Lean Procurement, Root Cause Analysis, Waste
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD39.5 Industrial procurement. 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:	Priesta Mayestika Karunia Devi
Date Deposited:	26 Jul 2024 01:16
Last Modified:	26 Jul 2024 01:16
URI:	http://repository.its.ac.id/id/eprint/108674

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