Penerapan Lean Thinking Untuk Mereduksi Waste Pada Proses Produksi Gula Di PT. PG Rajawali I Unit PG Krebet Baru

Putri, Vivy Brilliani (2018) Penerapan Lean Thinking Untuk Mereduksi Waste Pada Proses Produksi Gula Di PT. PG Rajawali I Unit PG Krebet Baru. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Pabrik Gula Rajawali 1 Unit PG. Krebet Baru merupakan perusahaan yang memproduksi gula berlokasi di Bululawang, Kabupaten Malang. Perusahaan menerapkan zero waste dalam pengembangan industri yang sesuai dengan penerapan lean thinking. Penelitian ini dimulai dengan identifikasi waste pada pengolahan produksi gula. Penentuan waste menggunakan Waste Assessment Relationship Matrix (WRM) dan Waste Assessment Questionnaire (WAQ). Hasil waste assesment dengan rangking tiga besar yaitu: defect sebesar 28,88%, waiting sebesar 24,35% unnecessary inventory sebesar 21,15%. Evaluasi dilakukan menggunakan metode value stream analysis tools (VALSAT) berdasarkan hasil perhitungan total bobot tertinggi yaitu process activity mapping (PAM) dengan skor 542,03. Pada process activity mapping, diketahui klasifikasi aktivitas antara lima jenis aktivitas yang dapat menimbulkan waste yaitu operation, transportation, inspection, storage, delay dengan hasil persentase Value added Activities (VA) sebesar 37%, Necessary Non Value added Activities (NNVA) sebesar 40% dan Non Value added Activities (NVA) 23%. Waste yang terjadi akan mengakibatkan kurang lancarnya proses produksi dan sehingga perlu dicari akar permasalahan dengan menggunakan root cause analysis (RCA). Hasil root cause analysis pada waste defect yaitu kurangnya pengawasan terhadap tebang angkut tebu dan proses produksi gula, serta kurang ketatnya inspeksi dan pengontrolan pada setiap stasiun produksi, sedangkan pada waste waiting yaitu perlunya penambahan inventory pada pos gawang dan gudang gula untuk mempercepat proses produksi gula, keterampilan operator sangat dibutuhkan ketika mesin bekerja tidak optimal, dan perlunya penjadwalan pembersihan setiap komponen pada setiap stasiun. Rekomendasi perbaikan dapat dilakukan dengan memperbaiki proses inspeksi serta pengawasan di setiap stasiun produksi, melakukan perbaikan proses pembersihan komponen, memperbaiki atau meningkatkan kinerja operator dan menambahkan 5S Red Tag. Perbaikan yang dilakukan peneliti bisa menjadi pertimbangan perusahaan dalam melakukan proses produksi gula yang efektif dan efisien.================PT Pabrik Gula Rajawali 1 Unit PG. Krebet Baru is a sugar-production company located in Bululawang, Kabupaten Malang. The company implements zero waste for development of industry in accordance with application of lean thinking. This research begins with identification of waste in process production of sugar. Waste use determination Waste Assessment Relationship Matrix (WRM) and Waste Assessment Questionnaire (WAQ). Result of waste assessment with high rank that is: defect to 28,88%, waiting to 24,35% unnecessary inventory to 21,15%. Evaluation was conducted for using value stream analysis tools method (VALSAT) based on the highest total weight calculation result is activity mapping process (PAM) with score 542,03. In the activity mapping process, it is known that the classification of activities between the five types of activities that can lead to waste is operation, transportation, inspection, storage, delay with percentage of Value added Activities (VA) of 37%, Necessary Non Value added Activities (NNVA) of 40% and Non Value added Activities (NVA) 23%. Waste that occurs will result in less smooth production process and so need to look for root cause by using root cause analysis (RCA). Result of root cause analysis in waste defect is lack of supervision of sugarcane transportation and sugar production process, and lack of strict inspection and control on each production station, while on waste waiting need additional inventory at post and sugar warehouse to accelerate of production process of sugar, operator skills needed when machine is not working optimally, and necessity of scheduling for cleaning of component at every station. Improvement recommendations can be made by improving inspection and monitoring processes at each production station, perform cleaning component processes, improving performance operator and adding 5S Red Tag. Improvements made by researchers can be a consideration of companies in the process of producing sugars effectively and efficiently.

Item Type: Thesis (Masters)
Uncontrolled Keywords: Lean, Waste, Process Activity Mapping, Value Stream Analysis Tools, Root Cause Analysis, Failure Mode and Effect Analysis
Subjects: H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
H Social Sciences > HD Industries. Land use. Labor > HD56.25 Industrial efficiency--Measurement. Industrial productivity--Measurement.
H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management
Divisions: Faculty of Business and Management Technology > Management Technology > 61101-(S2) Master Thesis
Depositing User: Vivy Brilliani Putri
Date Deposited: 22 Nov 2018 20:00
Last Modified: 21 Apr 2021 09:46
URI: https://repository.its.ac.id/id/eprint/53055

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