Upaya Perbaikan Kegiatan Operasional Pada Gudang Phonska Area II PT Petrokimia Gresik Dengan Pendekatan Lean Six Sigma

Wahyudin, Muhammad (2022) Upaya Perbaikan Kegiatan Operasional Pada Gudang Phonska Area II PT Petrokimia Gresik Dengan Pendekatan Lean Six Sigma. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Petrokimia Gresik merupakan salah satu perusahaan Badan Usaha Milik Negara yang memproduksi berbagai jenis pupuk. PT Petrokimia memiliki 8 gudang lini 1 yang digunakan dalam mendistribusikan pupuk di wilayah Jawa Bali dan salah satunya yaitu Gudang Phonska Area II. Saat ini Gudang Phonska Area II mengalami permasalahan operasional yaitu terdapat banyak pupuk yang tidak memenuhi spesifikasi dan diestimasikan perusahaan mengalami kerugian rata-rata mencapai Rp. 322.500.000 per-bulan. Selain itu terdapat permasalahan akibat terjadinya kegiatan yang tidak bernilai tambah atau pemborosan seperti waiting, over inventory, dan lainnya. Dalam menyelesaikan permasalahan pemborosan, penelitian ini berfokus pada pengurangan waste dan variabilitas produk dengan menggunakan lean six sigma. Pada tahap define, dilakukan identifikasi proses dengan menggunakan Value Stream Mapping (VSM), Process Activity Mapping (PAM), klasifikasi potensi yang menyebabkan waste, dan identifikasi Critical to Quality (CTQ). Kemudian pada tahap measure, dilakukan penilaian lean dengan menggunakan Waste Function Deployment, perhitungan nilai sigma, dan perhitungan biaya yang hilang akibat waste atau Cost of Poor Quality (COPQ). Pada tahap analyze dilakukan analisis permasalahan pada kondisi eksisting dan analisis hubungan hasil waste function deployment, six sigma dan COPQ. Pada tahap improve, dilakukan perancangan skenario alternatif perbaikan berupa rencana strategi pemeliharaan mesin bagging dan mesin jahit, perbaikan Standar Operasional Prosedur (SOP) quality control, serta kebijakan penalti mengenai kualitas karung dari supplier. Selain itu, dilakukan perbaikan kegiatan operasional seperti peletakkan kantong di dekat operator, manajemen pemeliharaan forklift, pergantian tipe belt conveyor, dan kebijakan penalti truck terlambat masuk gudang. Berdasarkan hasil perhitungan estimasi rencana perbaikan terjadi pengurangan yang cukup signifikan pada lead time dari 3434 detik menjadi 1154 detik. Dan terdapat peningkatan nilai sigma dari 4,4865 menjadi 4,679 pada kondisi perbaikan dengan penurunan cost of poor quality sebesar 47,85%.
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PT Petrokimia Gresik is one of the State-Owned Enterprises producing various fertilizers. PT Petrokimia has 8 line 1 warehouses used to distribute fertilizers in the Java-Bali area, and one of them is Phonska Area II Warehouse. Currently, the Phonska Area II Warehouse is experiencing operational problems, many fertilizers do not meet specifications, and it is estimated that the company suffers an average loss of Rp. 322,500,000 per month. In addition, there are problems due to activities that are not added value or waste, such as waiting, over inventory, and others. This research focuses on reducing waste and product variability by using lean six sigma to solve that problem. In the define stage, process identification is carried out using Value Stream Mapping (VSM), Process Activity Mapping (PAM), classification of potentials that cause waste, and identification of Critical to Quality (CTQ). Then in the measuring stage, lean assessment is carried out using Waste Function Deployment, sigma value calculation, and calculation of lost costs due to waste or Cost of Poor Quality (COPQ). In the analysis stage, problems in existing conditions are analyzed, and the relationship between the results of waste function deployment, six sigma, and COPQ. In the improvement stage, an alternative scenario is designed for improvement in the form of a bagging machine and sewing machine maintenance strategy plan, improvements to the Standard Operating Procedure (SOP) quality control, as well as a penalty policy regarding the quality of sacks from suppliers. In addition, improvements were made to operational activities such as placing bags near the operator, managing forklift maintenance, changing the type of conveyor belt, and a penalty policy for late trucks entering the warehouse. Based on the calculation of the estimated improvement plan, there was a significant reduction in lead time from 3434 seconds to 1154 seconds. And there is an increase in the sigma value from 4.4865 to 4.679 in improved conditions with a decrease in the cost of poor quality by 47.85%.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	DMAIC, Gudang, Lean Six Sigma, Waste Function Deployment
Subjects:	H Social Sciences > HF Commerce > HF5485 Warehouses--Management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	10 Feb 2026 07:30
Last Modified:	10 Feb 2026 07:30
URI:	http://repository.its.ac.id/id/eprint/132318

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