Peningkatan Efisiensi Proses Produksi Kapal dengan Pendekatan Lean-Green Manufacturing Menggunakan Green Value Stream Mapping (GVSM)

Yasnita, Faridah Rahma Yasnita (2026) Peningkatan Efisiensi Proses Produksi Kapal dengan Pendekatan Lean-Green Manufacturing Menggunakan Green Value Stream Mapping (GVSM). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Industri galangan kapal menghadapi tekanan dekarbonisasi akibat regulasi EEXI, CII, dan Net-Zero Framework IMO 2027, sementara Bengkel Permesinan PT Galangan Kapal yang mengerjakan komponen presisi tinggi berpotensi menghasilkan green waste dalam lima dimensi: waktu, energi, material, transportasi, emisi yang belum pernah dipetakan secara terintegrasi. Penelitian ini menggunakan Green Value Stream Mapping (GVSM), klasifikasi aktivitas VA, NVA, atau NNVA, Root Cause Analysis (RCA), dan ECRS pada product family piping flange. Hasil pemetaan GVSM current state menunjukkan proses produksi flange melalui 5 tahapan: turning & facing, turning diameter luar, drilling, chamfering, stamping dengan total lead time 82 menit, konsumsi energi 7,593 kWh, limbah scrap 1,353 kg, dan emisi karbon 16,139 kg CO2eq per siklus. Klasifikasi aktivitas menghasilkan 5 aktivitas VA, 4 NVA, dan 17 NNVA, dengan Process Cycle Efficiency (PCE) sebesar 39% dan Value-Added Energy Ratio (VAER) sebesar 40%. Analisis Pareto mengidentifikasi 12 aktivitas critical waste berupa waiting (setup mesin) dan motion (pembersihan scrap), yang melalui Fishbone Diagram dan 5 Whys ditemukan akar masalahnya yaitu belum adanya SOP pengelolaan scrap serta belum adanya program continuous improvement terstruktur untuk penerapan SMED dan 5S. Empat usulan perbaikan berbasis ECRS (chip tray, SMED, shadow board, setup sheet standar) berhasil menurunkan lead time menjadi sekitar 52 menit dengan PCE meningkat menjadi 62%, konsumsi energi turun menjadi 4,410 kWh dengan VAER meningkat menjadi 70%, dan emisi karbon turun sekitar 19% menjadi 13,106 kg CO2eq per siklus, meskipun volume scrap material belum berkurang secara kuantitas.
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The shipbuilding industry is facing decarbonization pressures due to EEXI, CII, and IMO 2027 Net-Zero Framework regulations, while PT Galangan Kapal Machinery Workshops working on high-precision components have the potential to produce green waste in five dimensions: time, energy, materials, transportation, emissions that have never been mapped in an integrated manner. This study uses Green Value Stream Mapping (GVSM), classification of VA, NVA, or NNVA activities, Root Cause Analysis (RCA), and ECRS in the Piping Flange product family. The results of the GVSM current state mapping show that the flange production process goes through 5 stages: turning & facing, turning outer diameter, drilling, chamfering, stamping with a total lead time of 82 minutes, energy consumption of 7,593 kWh, scrap waste of 1,353 kg, and carbon emission of 16,139 kg CO2eq per cycle. The activity classification resulted in 5 VA, 4 NVA, and 17 NNVA activities, with a Process Cycle Efficiency (PCE) of 39% and a Value-Added Energy Ratio (VAER) of 40%. The Pareto analysis identified 12 critical waste activities in the form of waiting (machine setup) and motion (scrap cleaning), which through the Fishbone Diagram and 5 Whys found the root of the problem, namely the absence of SOPs for scrap management and the absence of a structured continuous improvement program for the implementation of SMED and 5S. Four ECRS-based improvement proposals (chip tray, SMED, shadow board, standard setup sheet) managed to reduce lead time to about 52 minutes with PCE increasing to 62%, energy consumption dropping to 4,410 kWh with VAER increasing to 70%, and carbon emissions falling by about 19% to 13,106 kg CO2eq per cycle, although the volume of scrap material has not decreased in quantity.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Eco-Efficiency, Green Shipyard, GVSM, Lean-Green Manufacturing
Subjects:	T Technology > T Technology (General) > T385 Visualization--Technique T Technology > TD Environmental technology. Sanitary engineering > TD194.6 Environmental impact analysis T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. V Naval Science > VM Naval architecture. Shipbuilding. Marine engineering > VM298.5 Shipbuilding industri. Shipyards
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Faridah Rahma Yasnita
Date Deposited:	03 Aug 2026 01:31
Last Modified:	03 Aug 2026 01:31
URI:	http://repository.its.ac.id/id/eprint/141867

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