Rum, Catur Setianing (2019) Perbaikan Proses Produksi Welded Beam Dengan Metode Lean Manufacturing Pada Perusahaan Pengolahan Baja. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT X merupakan perusahaan konstruksi yang bergerak dalam bidang pengolahan baja yang memiliki produk unggulan berupa welded beam. Dalam melakukan proses produksinya, terdapat beberapa permasalahan berupa indikasi aktivitas yang tidak memberikan nilai tambah (waste) yang terjadi di lantai produksi seperti produk cacat, menunggu mesin diperbaiki dan proses assembly beam terhambat. Adanya waste menimbulkan kerugian baik dari segi biaya dan lead time produksi. Maka perusahaan perlu melakukan penerapan lean manufacturing untuk mereduksi waste tersebut. Langkah awal penerapan lean manufacturing dimulai dengan pemetaan aliran informasi dan material dengan metode Value Stream Mapping (VSM), identifikasi waste dengan Process Activity Mapping (PAM), identifikasi hubungan antar waste dengan Waste Relationship Matrix (WRM), menentukan akar penyebab waste dengan Root Cause Analysis (RCA) metode 5 Whys dan fishbone diagram. Selanjutnya dengan menggunakan lean assesment matrix 1 diperoleh waste kritis berupa defect, excessive processing, waiting dan over inventory. Dalam menerapkan lean manufacturing perusahaan dapat melakukan rekomendasi perbaikan berdasarkan hasil lean assesment matrix 2 yaitu pemasangan alat pengingat pengovenan flux, pemasangan alat pendeteksi perubahan tegangan dan pembuatan SOP penyambungan T. Hasil dari rekomendasi perbaikan dapat mereduksi waktu proses sebesar 31,5 menit, membuat lead time produksi menjadi 679,1 menit dan mereduksi defect rate sebesar 35,2%.
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PT X is a construction company engaged in steel processing which has superior products such as welded beam. In carrying out the production process, there are several problems in the form of indications of activities that do not provide added value (waste) that occur on the production floor such as defective products, waiting for repaired machines and delayed assembly of beam processes. The existence of waste causes losses both in terms of costs and production lead time. So companies need to implement lean manufacturing to reduce waste. The first step in implementing lean manufacturing starts with mapping the flow of information and material using the Value Stream Mapping (VSM) method, identifying waste with Process Activity Mapping (PAM), identifying relationships between waste using Waste Relationship Matrix (WRM), determining the root causes of waste with Root Cause Analysis (RCA) method 5 Whys and fishbone diagrams. Furthermore, using lean assessment matrix 1 will be obtained critical waste in the form of defects, excessive processing, waiting and over inventory. In implementing lean manufacturing the company can make improvements based on the results of lean assessment matrix 2 such as installing flux oven reminder, installation of voltage change detection devices and making SOP for T connections. The results of waste elimination action can reduce the processing time by 31.5 minutes, making production lead time becomes 679.1 minutes and reduces the defect rate by 35.2%
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Fishbone Diagram, Lean Assesment Matrix, Process Activity Mapping, Root Cause Analysis, Value Stream Mapping, Waste Relationship Matrix |
| Subjects: | T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures > TS167 Costs, Industrial T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | Catur Setianing Rum |
| Date Deposited: | 22 Jul 2026 00:39 |
| Last Modified: | 22 Jul 2026 00:39 |
| URI: | http://repository.its.ac.id/id/eprint/65048 |
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