Penerapan Lean Six Sigma Untuk Mereduksi Waste Pada Proses Pengantongan Urea: Studi Pada Pabrik-6, PT.Pupuk Kaltim.

Biu, Gilberth Sontanan (2026) Penerapan Lean Six Sigma Untuk Mereduksi Waste Pada Proses Pengantongan Urea: Studi Pada Pabrik-6, PT.Pupuk Kaltim. Masters thesis, Institut Teknologi Sepuluh Nopember.

Text 6032231102-Master_Thesis.pdf - Accepted Version Restricted to Repository staff only Download (4MB) | Request a copy

Abstract

Proses pengantongan urea di PT Pupuk Kaltim merupakan bagian krusial dari rantai produksi yang menerapkan push system berbasis rencana produksi. Data di unit Bagging-2 menghadapi peningkatan rasio produk reject dari 0,013% tahun 2023 menjadi 0,057% di tahun 2025. Kondisi ini menyebabkan pemborosan, tingginya biaya operasional, serta penurunan efisiensi dan potensi kepuasan pelanggan. Penelitian ini bertujuan mereduksi pemborosan pada proses pengantongan menggunakan pendekatan Lean Six Sigma melalui kerangkan DMAIC (Define, Measure, Analyze, Improve, Control). Tahap Define dilakukan dengan pemetaan Value Stream Mapping (VSM); tahap Measure menggunakan analisis Pareto dan pengukuran kinerja operasional, tahap Analyze mengaplikasikan Root Cause Analysis (RCA) dan Failure Mode and Effect Analysis (FMEA), tahap Improve melalui implementasi perbaikan teknis dan prosedural, dan tahap Control menggunakan Control Chart untuk menjaga stabilitas proses. Hasil penelitian menunjukkan bahwa waste dominan yang terjadi adalah waiting, defect, dan overprocessing yang dipengaruhi oleh ketidakstabilan aliran material dan performa peralatan. Implementasi perbaikan menghasilkan penurunan tingkat defect 0,141% menjadi 0,043 %, serta peningkatan stabilitas proses yang ditunjukkan oleh kenaikan nilai Cp serta dikonfirmasi melalui control chart dan nilai six sigma dari proses itu sendiri dari 2,89 σ menjadi 3,38 σ. Di sisi lain meskipun sistem push kurang selaras dengan prinsip dasar Lean Six Sigma yang berbasis pull, pendekatan ini terbukti efektif dalam meningkatkan efisiensi dan kualitas proses pengantongan urea.
========================================================================================================================================
The urea bagging process at PT Pupuk Kaltim represents a critical stage within the production chain, operating under a push system driven by production planning. Empirical data from the Bagging-2 unit indicate a notable increase in the reject rate, rising from 0.013% in 2023 to 0.057% in 2025. This trend reflects the presence of operational inefficiencies, leading to increased waste, higher operating costs, reduced process efficiency, and potential declines in customer satisfaction.This study aims to minimize waste in the bagging process by applying the Lean Six Sigma methodology through the DMAIC (Define, Measure, Analyze, Improve, Control) framework. The Define phase employs Value Stream Mapping (VSM) to visualize the process flow. The Measure phase integrates Pareto analysis and operational performance metrics to identify critical issues. The Analyze phase utilizes Root Cause Analysis (RCA) and Failure Mode and Effect Analysis (FMEA) to determine underlying causes. The Improve phase focuses on the implementation of technical and procedural enhancements, while the Control phase applies Control Charts to ensure sustained process stability.The findings reveal that the predominant forms of waste are waiting, defects, and overprocessing, primarily driven by instability in material flow and equipment performance. The implementation of improvements resulted in a significant reduction in the defect rate from 0.141% to 0.043%, as well as an increase in process stability, as indicated by an increase in the Cp value and validated through control chart and the process’s Six Sigma capability, which improve from 2.89σ to 3.38σ. Although the push system is inherently less aligned with the pull-based principles of Lean Six Sigma, the results demonstrate that its structured application remains effective in improving both efficiency and quality within the urea bagging process.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Sistem dorong, Lean Six Sigma, Value Stream Mapping, Analisa akar masalah, Failure Mode and Effect Analysis, Control Chart, Efisiensi pengantongan, Push system, Root Cause Analysis, Process efficiency.
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. T Technology > TS Manufactures > TS195 Packaging
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Gilberth Sontanan Biu
Date Deposited:	10 Jun 2026 11:09
Last Modified:	10 Jun 2026 11:09
URI:	http://repository.its.ac.id/id/eprint/133706

Actions (login required)

View Item