Penerapan Lean Dengan Genba Shikumi Untuk Mengurangi Pemborosan Pada Proses Produksi Di PT Sanghiang Perkasa

Nurhaliza, Via Ayu (2025) Penerapan Lean Dengan Genba Shikumi Untuk Mengurangi Pemborosan Pada Proses Produksi Di PT Sanghiang Perkasa. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Sanghiang Perkasa (Kalbe Nutritionals) merupakan perusahaan yang bergerak di manufaktur susu bubuk dan nutrisi. Dalam kondisi existing proses produksi masih ditemukan berbagai bentuk pemborosan khususnya pada aktivitas penyiapan Raw Material (RM). Proses penyiapan masih dilakukan secara manual memunculkan indikasi adanya non-value-added activity. Oleh karena itu, penelitian ini bertujuan mengidentifikasi pemborosan dan merancang solusi perbaikan proses penyiapan dengan pendekatan lean manufacturing meliputi Value Stream Mapping (VSM) dan Process Activity Mapping (PAM) untuk memetakan proses penyiapan. Identifikasi waste kritis dilakukan menggunakan metode genba shikumi karena pendekatan ini mampu mengkaji proses secara langsung (genba) dan menghasilkan prioritas pemborosan. Waste kritis didapatkan dari skor tertinggi matriks kepentingan mutlak di genba shikumi yang dianalisis berdasarkan prinsip pareto. Ditemukan dua waste kritis yang berasal dari proses non-timbang, yaitu aktivitas setting scanner dan menjemput RM. Kedua waste ini termasuk kritis karena frekuensi yang sering terjadi, dampaknya besar terhadap keseluruhan proses penyiapan, dan memiliki keterkaitan dengan pemborosan yang lain. Oleh karena itu, waste kritis menjadi perhatian untuk dicari akar permasalahan dan dilakukan perbaikan. Akar permasalahan dianalisis menggunakan 5 Why’s, didapatkan struktur bangunan dari proses penyiapan yang menghalangi jaringan untuk permasalahan aktivitas setting scanner. Selain itu, permasalahan penjemputan RM oleh operator vacuum dikarenakan belum adanya trigger point yang mengatur pengiriman oleh operator pengiriman dimana saat ini hanya menggunakan perkiraan jam pengiriman. Diusulkan 2 rekomendasi perbaikan untuk mengatasi stuktur bangunan yang menghalangi jaringan, yaitu pembuatan Wi-Fi yang dialokasikan khusus proses penyiapan dan penggunaan alat docking crade yang kompatibel terhadap ethernet. Sedangkan akar permasalahan trigger point pengiriman diusulkan 3 rekomendasi, yaitu penggunaan HT, penggunaan andon, dan penerapan digital kanban. Pemilihan rekomendasi dilakukan melalui lean matrix 2 untuk menentukan prioritas implementasi. Hasil analisis menunjukkan akar permasalahan dari struktur bangunan proses penyiapan menjadi prioritas utama menjadi prioritas pertama, dan dilanjutkan dengan akar permasalahan prosedur pengiriman RM oleh operator pengiriman. Dengan demikian, rekomendasi penyediaan Wi-Fi khusus proses penyiapan menjadi prioritas pertama perusahaan untuk menyelesaikan permasalahan setting scanner, kemudian dilanjutkan dengan penerapan digital kanban yang berkontribusi mengatasi penjemputan RM.
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PT Sanghiang Perkasa (Kalbe Nutritionals) is a company engaged in the manufacturing of powdered milk and nutritional products. In its current production process, several forms of waste are still present, particularly in the Raw Material (RM) preparation stage. The preparation process is still carried out manually, which indicates the existence of non-value-added activities. Therefore, this study aims to identify waste and design improvement solutions for the preparation process using a lean manufacturing approach. Value Stream Mapping (VSM) and Process Activity Mapping (PAM) are applied to map and evaluate the current process. To identify critical waste, the genba shikumi method is used, as it enables direct observation of the process (genba) and helps prioritize the types of waste. The critical waste is identified based on the highest score in the absolute importance matrix from genba shikumi and further analyzed using the pareto principle. Two critical waste activities were identified within the non-weighing process, namely the scanner setup activity and the transportation of RM. These two types of waste are considered critical due to their frequent occurrence, significant impact on the overall preparation process, and connection to other forms of waste. Therefore, it is important to identify the root causes and implement improvements. Using the 5 Why’s method, the root cause of the scanner setting issue was found to be the building structure in the preparation area that obstructs the network. Meanwhile, the issue related to the pickup of RM by the vacuum operator was caused by the absence of a trigger point to manage deliveries. Currently, deliveries are only based on estimated times. Two improvement recommendations are proposed to solve the network obstruction problem: providing a dedicated Wi-Fi connection for the preparation process and using a docking cradle that is compatible with Ethernet. For the delivery trigger issue, three recommendations are suggested: using Handy Talkie (HT), installing an andon system, and applying a digital kanban system. The selection of recommendations was carried out using a lean matrix 2 to prioritize implementation. The analysis shows that the root cause related to the building structure in the preparation process should be addressed first, followed by improvements to the delivery procedure for RM. Therefore, the provision of dedicated Wi-Fi for the preparation process is set as the top priority to resolve the scanner setting issue, followed by the implementation of a digital kanban system to improve RM pickup activities.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Genba Shikumi, Lean, VSM, PAM, Lean Matrix 2, Genba Shikumi, Lean, VSM, PAM, Lean Matrix 2.
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:	Via Ayu Nurhaliza
Date Deposited:	30 Jul 2025 06:40
Last Modified:	30 Jul 2025 06:40
URI:	http://repository.its.ac.id/id/eprint/123407

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