Perancangan perbaikan proses produksi bodi mobil Daihatsu Xenia dengan lean manufacturing di Pt. Inti Pantja Press Industri

Isnain, Satria Khalif (2017) Perancangan perbaikan proses produksi bodi mobil Daihatsu Xenia dengan lean manufacturing di Pt. Inti Pantja Press Industri. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. Inti Pantja Press Industri merupakan produsen komponen-komponen bodi mobil Daihatsu merk Xenia, Terios, Ayla, Sirion dan Sigra berlokasi di Bekasi. Industri otomotif memiliki potensi bisnis yang positif karena permintaan mobil yang terus bertambah setiap waktu. Namun, agar dapat memenangkan kompetisi bisnis yang saat ini semakin berat, maka PT IPPI harus dapat menjalankan produksi secara lebih efisien. Hasil observasi awal pada proses produksi Daihatsu Xenia terindikasi beberapa masalah yang terkait dengan adanya pemborosan (waste) misalnya bottleneck dan cacat. Berdasarkan permasalahan yang terjadi, pendekatan lean manufacturing dipergunakan untuk menyelesaikan permasalahan tersebut. Pertama-tama Pemborosan diidentifikasi dengan Value Stream Mapping dan Process Activity Mapping. Kemudian Borda Count Method dipergunakan untuk menentukan pemborosan (waste) kritis pada lantai produksi yang hasilnya yaitu waste waiting, defects dan overproduction yang menyebabkan terjadinya over inventory finish part. Metode 5Whys kemudian dipergunakan untuk mencari akar penyebab pemborosan (waste). Berdasarkan Failure Mode and Effect Analysis diketahui akar penyebab waste tertinggi adalah operator tidak membersihkan dies sebelum proses press, lifetime komponen yang telah habis namun tidak diganti dan karat pada produk finish part. Rekomendasi perbaikan yang dapat diusulkan yaitu penerapan metode Poka Yoke dengan instalasi sensor dan peralatan di mesin press dan pemasangan wrapping pada pallet produk finish part. Dengan analisa Net Present Value menunjukkan bahwa kedua usulan rekomendasi perbaikan layak untuk dilakukan oleh perusahaan. ================================================================================================================= PT. Inti Pantja Press Industri, which is located in Bekasi, is an automotive body parts and components manufacturer of Xenia, Terios, Ayla, Sirion, and Siegra that supplies to Astra Daihatsu Motor Company. Potential market for automotive is continuously growing which is positive signal for automotive businesses. However nowadays competition is also getting stronger. Therefore PT Inti Pantja Press Industri should efficiently manage their production. One way is by reducing and eliminating waste in its production. Production process in PT. Inti Pantja Press Industri is still having several problems. Based on early observation there are bottleneck in subassy processes and also defective product. Reffering to these problems, it can be indicated that there are several waste in production process of PT. Inti Pantja Press Industri. Therefore, Lean Manufacturing approach is utilized to reduce or eliminate waste in production processes. First, various waste are identified using Value Stream Mapping and Process Activity Mapping. Borda Count Method is used for determining critical waste that occur, they are as follow: waste waiting, defect, and overproduction that cause over inventory finish product. Then, 5Whys Analysis specifies root causes of waste waiting and waste defect. By using Failure Mode and Effect Analysis, highest priority of root causes can be selected, which are operator do not clean dies before press process, operator do not replace components that has already over its lifetime (wear) and rust on finish product part. Recommendations for improvements are conducted by implementating Poka Yoke method, they are: installation of sensors and equipment in Press machines and wrapping finish part product. Finally, Net Present Value analysis is conducted to ensure that recommendations are feasible.

Item Type: Thesis (Masters)
Uncontrolled Keywords: Lean manufacturing; value stream mapping; Process activity mapping; Root cause analysis; Failure mode and effect analysis; Poka yoke
Subjects: H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
Divisions: 61101-Magister Management Technology
Depositing User: SATRIA KHALIF ISNAIN
Date Deposited: 24 Mar 2017 04:57
Last Modified: 24 Mar 2017 04:57
URI: https://repository.its.ac.id/id/eprint/2609

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