Penerapan Lean Manufacturing Untuk Meminimasi Waste Pada Proses Produksi Pot Cream

Fayed, Dody Al (2019) Penerapan Lean Manufacturing Untuk Meminimasi Waste Pada Proses Produksi Pot Cream. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT X merupakan salah satu industri manufaktur yang menggunakan biji plastik sebagai bahan baku utama dalam pembuatan pot cream. Dalam proses produksi industri ini, terdapat permasalahan yang menyebabkan ouput produksi yang dihasilkan tidak sesuai dengan target permintaan pelanggan dan complain rate dari pelanggan diatas standar perusahaan. Permasalahan yang muncul dalam proses produksi antara lain adalah produk defect, penumpukan WIP, downtime akibat mesin mengalami kerusakan, dll. Penelitian ini bertujuan untuk mengidentifikasi dan mengurangi waste dengan menerapkan Lean Manufacturing pada proses produksi pot cream di PT X. Waste atau pemborosan merupakan kegiatan yang tidak memberikan nilai tambah. Langkah awal penelitian dilakukan dengan mengidentifikasi pemborosan menggunakan Operation process Chart (OPC), Value Stream Mapping (VSM), dan Process Activity Mapping (PAM). Setiap pemborosan akan dianalisis akar penyebab dengan 5 Why’s method. Berdasarkan Lean Matrix 1, didapatkan 3 waste kritis yaitu defect jenis appearance pada pot cream, output produk yang diproduksi melebihi dari defect tolerance, dan gerakan berlebih saat menyusun base atas. Dari hasil Lean Matrix 2, terdapat 3 rekomendasi perbaikan yang dipilih berdasarkan hasil diskusi dengan perusahaan, yaitu Poka Yoke, 5S, dan mekanisme pemilihan jenis perawatan untuk mold. Dengan menerapkan tiga rekomendasi perbaikan, jumlah kerugian yang dikeluarkan oleh PT X akibat produk defect mengalami penurunan sebesar Rp1.141.772.400,00.
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PT X is one of the manufacturing industry that used plastic as the main material in the production process of pot cream. In the production process, production output cannot fulfill the customer demand targets and customer complain rate based on the company standard. Its caused by defects, work in process, downtime, etc. This research aims to identify and reduce waste by applying Lean Manufacturing in the production process of pot cream at PT X. The initial step of the research is to identify waste using the Operation Process Chart (OPC), Value Stream Mapping (VSM), and Process Activity Mapping (PAM). The Waste Assessment Model (WAM) is conducted to give weight and show the relationship between waste. The root causes of each waste will be analyzed using 5 Why's Method. Based on Lean Matrix 1, there were 3 critical wastes, namely defect type appearance in pot cream, product output produced exceeded defect tolerance, and excessive movement when composing the upper base. Based on Lean Matrix 2, there are 3 recommendations for improvement that are selected based on the results of discussions with the company, namely Poka-Yoke, 5S, and the mechanism for selecting types of treatments for mold. Therefore, implementing three recommendations for improvement can decrease the number of losses by Rp1.141.772.400,00.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Manufacturing, Lean Assessment Matrix, Value Stream Mapping (VSM), Waste Assessment Model (WAM), Waste.
Subjects:	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:	DODY AL FAYED
Date Deposited:	22 Jul 2026 00:49
Last Modified:	22 Jul 2026 00:49
URI:	http://repository.its.ac.id/id/eprint/65327

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