Analisis Waste Pada Proses Produksi Teh Hitam CTC Melalui Pendekatan Lean-Ergonomic Dalam Mendukung Continuous Improvement (Studi Kasus Pabrik Teh Wonosari)

Utami, Widya Pranata (2026) Analisis Waste Pada Proses Produksi Teh Hitam CTC Melalui Pendekatan Lean-Ergonomic Dalam Mendukung Continuous Improvement (Studi Kasus Pabrik Teh Wonosari). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Perkebunan Nusantara I Regional 5 Pabrik Teh Wonosari merupakan industri pengolahan teh hitam CTC yang dalam proses produksinya masih ditemukan waste seperti aktivitas non-value added yang tinggi dan kondisi kerja yang kurang ergonomis. Penelitian ini bertujuan untuk menganalisis efisiensi proses produksi serta menghasilkan usulan perbaikan yang dapat mengatasi akar penyebab waste kritis yang terjadi dengan pendekatan Lean–Ergonomic. Pemetaan proses dilakukan menggunakan Operation Process Chart (OPC), Value Stream Mapping (VSM), dan Process Activity Mapping (PAM) untuk mengidentifikasi aktivitas Value Added (VA), Necessary Non-Value Added (NNVA), dan Non-Value Added (NVA), kemudian penentuan waste kritis dilakukan menggunakan Genba Shikumi. Analisis dilanjutkan dengan Fishbone Diagram untuk mencari akar penyebab serta evaluasi ergonomi menggunakan Biomekanika Statis dan Rapid Entire Body Assessment (REBA). Berdasarkan hasil tersebut, disusun rekomendasi perbaikan yang diprioritaskan menggunakan Modified Lean Matrix. Hasil penelitian menunjukkan bahwa usulan perbaikan yang dihasilkan mampu mengurangi waste kritis melalui eliminasi aktivitas non-value added, penyederhanaan aliran material, penurunan cycle time dan production lead time, serta berpotensi memperbaiki kondisi ergonomi pekerja dalam mendukung continuous improvement.
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PT Perkebunan Nusantara I Regional 5 Wonosari Tea Factory is a CTC black tea processing industry in which waste is still found in the production process, such as high non-value-added activities and less ergonomic working conditions. This study aims to analyze the efficiency of the production process and propose improvement recommendations that can address the root causes of critical waste through a Lean–Ergonomic approach. Process mapping was carried out using the Operation Process Chart (OPC), Value Stream Mapping (VSM), and Process Activity Mapping (PAM) to identify Value Added (VA), Necessary Non-Value Added (NNVA), and Non-Value Added (NVA) activities, while critical waste was determined using Genba Shikumi. The analysis was further conducted using a Fishbone Diagram to identify the root causes of waste and ergonomic evaluations using Static Biomechanics and Rapid Entire Body Assessment (REBA). Based on the findings, improvement recommendations were developed and prioritized using the Modified Lean Matrix. The results showed that the proposed improvements are capable of reducing critical waste through the elimination of non-value-added activities, streamlining material flow, reducing cycle time and production lead time, and potentially improving workers' ergonomic conditions to support continuous improvement.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Genba Shikumi, Lean-Ergonomic, Modified Lean Matrix, Teh Hitam CTC, Waste, CTC Black Tea
Subjects:	T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) 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:	Widya Pranata Utami
Date Deposited:	03 Aug 2026 09:50
Last Modified:	03 Aug 2026 09:50
URI:	http://repository.its.ac.id/id/eprint/142264

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