Pengembangan Lean Waste Reduction Framework pada Implementasi Lean Manufacturing

Ilmi, Innastya Hafshah Irbatul (2026) Pengembangan Lean Waste Reduction Framework pada Implementasi Lean Manufacturing. Masters thesis, Institut Teknologi Sepuluh Nopember.

Text 6010241086-Master_Thesis.pdf - Accepted Version Restricted to Repository staff only Download (8MB) | Request a copy

Abstract

Implementasi Lean Manufacturing memerlukan alat bantu yang tidak hanya mampu mengidentifikasi pemborosan secara komprehensif, tetapi juga menelusuri akar penyebab dan menentukan prioritas perbaikannya. Value Stream Mapping (VSM) tradisional masih berfokus pada tujuh jenis waste. Penelitian sebelumnya telah mengembangkan Extended Value Stream Mapping (EVSM) dengan mempertimbangkan aspek ergonomi dan non-utilized talent, tetapi belum mengakomodasi Health, Safety, and Environment (HSE). Selain itu, EVSM belum menyediakan mekanisme lanjutan untuk memprioritaskan tindakan perbaikan berdasarkan hubungan antara waste, akar penyebab, efektivitas tindakan, dan tingkat kesulitan implementasi. Oleh karena itu, penelitian ini mengembangkan Lean Waste Reduction Framework melalui perluasan EVSM menjadi sembilan jenis waste dengan menambahkan aspek HSE serta modifikasi Quality Function Deployment (QFD) agar menghasilkan prioritas rencana aksi pengurangan waste yang lebih aplikatif. Framework ini mencakup identifikasi waste, penentuan waste dominan, analisis akar penyebab, identifikasi alternatif perbaikan, dan prioritisasi rencana aksi berdasarkan rasio Effectiveness to Difficulty (ETD), kemudian diaplikasikan pada industri pengecoran bogie sebagai studi kasus. Hasil penerapan Lean Waste Reduction Framework menunjukkan bahwa tahap 9 Waste EVSM berhasil mengidentifikasi 7 jenis waste yang terjadi di perusahaan. Selanjutnya, Modified QFD mengidentifikasi waste Waiting sebagai waste yang paling dominan diikuti dengan waste HSE. Temuan ini menunjukkan bahwa aspek kesehatan, keselamatan, dan lingkungan merupakan faktor penting yang perlu diperhatikan di industri ini. Modified QFD juga menghasilkan 7 akar penyebab dominan yang memicu terjadinya waste, serta 10 rencana aksi pengurangan waste. Tiga prioritas tindakan pengurangan waste adalah penguatan sistem pengendalian penggunaan APD melalui standardisasi prosedur dan pengawasan kepatuhan pekerja, implementasi sistem monitoring downtime dan analisis kegagalan mesin, serta penerapan program preventive maintenance terintegrasi berbasis histori kerusakan dan jadwal pemeliharaan berkala.
=====================================================================================================================================
The implementation of Lean Manufacturing requires tools that are not only capable of comprehensively identifying waste but also of tracing its root causes and determining improvement priorities. Traditional Value Stream Mapping (VSM) remains focused on seven types of waste. Previous studies have developed Extended Value Stream Mapping (EVSM) by incorporating ergonomic aspects and non-utilized talent; however, Health, Safety, and Environment (HSE) aspects have not yet been accommodated. Furthermore, EVSM does not provide a follow-up mechanism for prioritizing improvement actions based on the relationships among waste, root causes, action effectiveness, and implementation difficulty. Therefore, this study develops a Lean Waste Reduction Framework by extending EVSM to cover nine types of waste through the addition of HSE and by modifying Quality Function Deployment (QFD) to generate more applicable priorities for waste reduction action plans. The framework encompasses waste identification, determination of dominant waste, root cause analysis, identification of improvement alternatives, and prioritization of action plans based on the Effectiveness to Difficulty (ETD) ratio. It is subsequently applied to the bogie casting industry as a case study. The application of the Lean Waste Reduction Framework shows that the 9 Waste EVSM stage successfully identified seven types of waste occurring in the company. The Modified QFD analysis identified waiting as the most dominant waste, followed by HSE waste. This finding indicates that health, safety, and environmental aspects are important factors that require attention in this industry. The Modified QFD also identified seven dominant root causes contributing to waste generation and generated ten waste reduction action plans. The three highest-priority waste reduction actions are strengthening the control system for personal protective equipment use through standardized procedures and worker compliance supervision, implementing a downtime monitoring system and machine failure analysis, and establishing an integrated preventive maintenance program based on historical failure records and scheduled maintenance.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	9 Waste, Extended VSM, Lean Manufacturing, Modified QFD
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Innastya Hafshah Irbatul Ilmi
Date Deposited:	28 Jul 2026 02:15
Last Modified:	28 Jul 2026 02:15
URI:	http://repository.its.ac.id/id/eprint/138092

Actions (login required)

View Item