Material Handling Determination And Inventory Calculation Using Lean Methodology Approach

Wicaksana, Winahyu Tyas (2018) Material Handling Determination And Inventory Calculation Using Lean Methodology Approach. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. X adalah sebuah perusahaan yang bergerak di bidang Fast Moving Consumer Good di Indonesia. Penelitian dilakukan di dalam salah satu pabrik yang dimiliki, bertempat di daerah Rungkut, Surabaya. Di dalam komplek pabrik terdapat beberapa blok, dan penelitian dilakukan di salah satu blok bernama PW2 (Personal Wash) dimana produk yang dihasilkan adalah sabun batangan. Terdapat permasalahan persediaan di dalam proses produksi di PW2, dimana alur pasokan bahan perantara dari PW1 tidak stabil dan sering mengalami keterlambatan dan menyebabkan berhentinya proses produksi. Setelah dilakukan perhitungan persediaan menggunakan pendekatan persediaan aman, diketahui persediaan paling efisien mungganakan satuan 1000 kg kantung besar, dan memerlukan ruang sebesar 100 palet. Dalam Value Stream Mapping yang dilakukan untuk memetakan proses perpindahan material, diketahui bahwa lead time sebanyak 785 menit. Process Activity Mapping kemudian dibangun untuk menganalisa lebih jauh, dan diketahui bahwa waktu value added sebanyak 59 menit, sedangkan non value added sebanyak 36 menit. Dari kedua analisa tersebut, diketahui jenis pemborosan yang terjadi adalah motion, transportation, inventory, dan waiting. Analisa akar masalah menggunakan metode 5 why’s dilakukan untuk menentukan akar permasalahan dari pembrosan yang terjadi. Saran perbaikan kemudian diberikan menggunakan pendekatan lean dan diestimasikan dapat merubah lead time menjadi lebih pendek yaitu sebanyak 546,5 menit. =============================================================================================== PT. X is a well known Fast Moving Consumer Good (FMCG) company that has several factory in Indonesia. The research is done in one of the factory located in Rungkut, Surabaya. The research is done in one of the block in the factory which is PW2 whose products are bar soap. In PW2, inventory problem often occured caused by unstable intermediary material flow from PW1. First, an inventory calculation of safety stock calculation is done, and the result show that the most efficient is by using 1000kg big bag. The space that is needed is for 100 big bag and a new layout plan in the substore is constructed. In the Value Stream Mapping, it is known that in the material handling activity, the lead time is 785 minutes. To further analyze the material handling activity, the Process Activity Mapping is done. From the VSM and PAM, it is known that the waste in the material handling activity are motion, transportation, inventory, and waiting. Root Cause Analysis is done to determine the root cause of the wastes. Using lean methodology approach, the lead time for the material handling activity can be reduced into 546,5 minutes.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Lean Methodology, Safety Stock, Inventory Calculation, Root Cause Analysis
Subjects: H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions: Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: Wicaksana Winahyu Tyas
Date Deposited: 15 Jul 2021 23:17
Last Modified: 15 Jul 2021 23:17
URI: https://repository.its.ac.id/id/eprint/55490

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