Implementasi Perbaikan Berkelanjutan (Kaizen) pada Proses Suplai Engine di Line Produksi Engine Dress Up dengan Metode PDCA Toyota Plant 1 Karawang

Titanullah, Anastyar (2023) Implementasi Perbaikan Berkelanjutan (Kaizen) pada Proses Suplai Engine di Line Produksi Engine Dress Up dengan Metode PDCA Toyota Plant 1 Karawang. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Tingginya lead time pada proses suplai engine sebesar 8.08 menit mengakibatkan rendahnya efisiensi pada proses suplai engine sebesar 37.9% memberikan dampak terhadap meningkatnya jumlah kebutuhan manpower serta biaya operasional produksi. Hal tersebut disebabkan oleh adanya bottleneck pada proses prepare engine yang menyumbang cycle time sebesar 259.6 detik. Oleh karena itu, diperlukan pendekatan dengan mengimplementasikan konsep kaizen dengan penerapan langkah dasar PDCA (plan-do-check-action) dengan tujuan meningkatkan efisiensi proses suplai engine pada line produksi Engine Dress Up. Penelitian dilakukan di Departement Assy Production #1 & PIO Karawang Plant 1 PT. Toyota Motor Manufacturing Indonesia pada proses suplai untuk tipe engine GD AT, GD MT, TR AT, TR MT, GR. Sebelum perbaikan, durasi proses suplai engine adalah sebesar 8.08 menit dengan kebutuhan manpower sebesar 5 orang. Hasil implementasi perbaikan (Kaizen) pada prepare engine dengan metode PDCA memberikan dampak yang signifikan terhadap penurutan cycle time pada prepare engine sebesar 238.8 detik, pada proses suplai engine menjadi sebesar 7.73, kebutuhan manpower 4 orang, dan peningkatan efisiensi yang mencapai 50.72% serta memberikan penghematan biaya sebesar Rp. 3,669,111.
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The high lead time in the engine supply process of 8.08 minutes resulted in a low efficiency in the engine supply process of 37.9% which had an impact on increasing the number of manpower requirements and production operational costs. This is caused by a bottleneck in the prepare engine process which contributes to a cycle time of 259.6 seconds. Therefore, an approach is needed to implement the kaizen concept by implementing the PDCA (plan-do-check-action) basic steps with the aim of increasing the efficiency of the engine supply process on the Engine Dress Up production line. The research was conducted at the Assy Production Department #1 & PIO Karawang Plant 1 PT. Toyota Motor Manufacturing Indonesia in the supply process for engine types GD AT, GD MT, TR AT, TR MT, GR. Before the repair, the duration of the engine supply process was 8.08 minutes with a manpower requirement of 5 people. The results of the implementation of improvements (Kaizen) on the prepared engine with the PDCA method have a significant impact on reducing the cycle time on the prepared engine by 238.8 seconds, on the engine supply process it becomes 7.73, the manpower requirement is 4 people, and the efficiency increase reaches 50.72% and provides savings costs Rp. 3,669,111.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Efisiensi, PDCA, Kaizen, Manpower, Efficiency
Subjects:	T Technology > TS Manufactures T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	Anastyar Titanullah
Date Deposited:	07 Feb 2023 06:47
Last Modified:	07 Feb 2023 06:47
URI:	http://repository.its.ac.id/id/eprint/96374

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