Penerapan Lean Manufacturing dengan Metode Value Stream Mapping dan Lean Assessment Matrix untuk Mereduksi Waste di Area Produksi Pakan Ternak Unggas

Puspitasari, Rizki (2025) Penerapan Lean Manufacturing dengan Metode Value Stream Mapping dan Lean Assessment Matrix untuk Mereduksi Waste di Area Produksi Pakan Ternak Unggas. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Industri peternakan di Indonesia memiliki peran penting dalam pertumbuhan ekonomi, khususnya dalam pemenuhan kebutuhan pangan melalui produk unggas. PT X, sebagai perusahaan manufaktur pakan ternak multinasional, menghadapi berbagai permasalahan dalam proses produksinya. Beberapa masalah yang dihadapi termasuk kerusakan mesin pada mesin dosing selama 13 menit dan mesin pellet mill selama 20 menit yang menyebabkan penumpukan bahan baku dan terjadinya waiting time, serta bottleneck pada kapasitas pellet mill (37,5 ton/batch) yang memperlambat proses produksi dengan demand rata-rata yaitu 1080 ton/hari sedangkan kemampuan produksi saat ini hanya dapat memproduksi 900 ton/hari. Selain itu, banyak ditemukan tenaga kerja yang terlihat menganggur dan banyak berbincang (3-5 pekerja setiap hari nya yang terlihat idle) sehingga menghambat proses produksi dan proses bagging menjadi lebih lama dengan kenaikan waktu selama 4,3 menit, ditemukan sekitar 50 kg bahan baku yang rusak di gudang dalam kurun waktu satu minggu. Penelitian ini bertujuan untuk menerapkan Lean Manufacturing dengan metode Value Stream Mapping (VSM) dan Lean Assessment Matrix untuk mengidentifikasi waste lainnya yang terjadi dan mereduksi waste di area produksi PT X. Metode 5 Why’s digunakan untuk analisis akar penyebab, sementara Process Activity Mapping (PAM) digunakan untuk memetakan aliran proses produksi secara rinci. Penelitian ini diawali dengan memetakan proses produksi eksisting dengan metode Value Stream Mapping dan Process Activity Mapping. Selanjutnya, identifikasi waste kritis dan akar penyebab permasalahan menggunakan metode Lean Assessment Matrix dan 5 why’s. Berdasarkan hasil pemetaan lean matrix 1, diperoleh 5 waste kritis yaitu bottleneck pada proses pelleting, pekerja bagging yang melakukan aktivitas tidak bernilai tambah, bottleneck pada proses bagging, fisik produk yang belang akan di proses ulang. Selanjutnya, berdasarkan lean matrix 2, terdapat 5 rekomendasi perbaikan terpilih yaitu membuat SOP sistem gaji yang akan mengikuti jumlah produk yang berhasil dikemas oleh pekerja bagging, pengadaan mesin pellet mill baru, membuat dashboard sistem pencatatan data kerusakan, pembentukan tim audit pelaksanaan prosedur kontrol kualitas penyimpanan dan kontrol mesin, pembuatan sanksi terhadap pengabaian prosedur kontrol.
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The livestock industry in Indonesia plays an important role in economic growth, especially in meeting food needs through poultry products. PT X, as a multinational animal feed manufacturing company, faces various problems in its production process. Some of the problems faced include machine failures on the dosing machine for 13 minutes and the pellet mill machine for 20 minutes which causes a buildup of raw materials and waiting time, as well as a bottleneck in the pellet mill capacity (37.5 tons/batch) which slows down the production process with an average demand of 1080 tons/day while the current production capacity can only produce 900 tons/day. In addition, many workers were found to be unemployed and talking a lot (3-5 workers each day who were seen idle) so that it hampered the production process and the bagging process became longer with an increase in time of 4.3 minutes, around 50 kg of raw materials were found damaged in the warehouse within a week. This study aims to apply Lean Manufacturing with the Value Stream Mapping (VSM) and Lean Assessment Matrix methods to identify other waste that occurs and reduce waste in the production area of PT X. The 5 Why’s method is used for root cause analysis, while Process Activity Mapping (PAM) is used to map the production process flow in detail. This study began by mapping the existing production process with the Value Stream Mapping and Process Activity Mapping methods. Furthermore, identification of critical waste and root causes of the problem using the Lean Assessment Matrix and 5 why's methods. Based on the results of the lean matrix 1 mapping, 5 critical wastes were obtained, namely bottlenecks in the pellet formation process, bagging workers who carry out non-value-added activities, bottlenecks in the bagging process, physical products that are uneven will be reprocessed. Furthermore, based on lean matrix 2, there are 5 selected improvement recommendations, namely creating SOPs related to the salary system that will follow the number of products successfully packaged by bagging workers, increasing the capacity of the pellet mill machine by procuring new machines, creating a system dashboard for recording damage data, forming an audit team for the implementation of quality control procedures for storing raw materials and machine control, creating sanctions for ignoring control procedures.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Manufacturing, 5 Whys, Value Stream Mapping (VSM), Lean Assessment Matrix, Process Activity Mapping (PAM)
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Rizki Puspitasari
Date Deposited:	21 Jul 2025 03:39
Last Modified:	21 Jul 2025 03:39
URI:	http://repository.its.ac.id/id/eprint/120211

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