Implementasi Lean Manufacturing Dalam Mereduksi Waste Pada Sistem Produksi Karpet Mobil Di Pt. Classic Automotive Manufacturing

Nurfi, Elfaruri (2016) Implementasi Lean Manufacturing Dalam Mereduksi Waste Pada Sistem Produksi Karpet Mobil Di Pt. Classic Automotive Manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember Surabaya.

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Abstract

PT. Classic Automotive Manufacturing (PT. CAM) merupakan salah satu perusahaan penghasil karpet mobil di Surabaya. Produk yang dibuat oleh PT.CAM bersifat Make to Order. PT. CAM menjadi salah satu pemasok karpet mobil di tujuh distributor aksesoris yang berlokasi di Jepang. Prosentase pengiriman terbesar ialah pada perusahaan Faltec America (FA) yang merupakan distributor aksesoris mobil Nissan Juke. Dalam menjalankan sistem produksinya PT.CAM mengalami beberapa kendala diantaranya tidak tercapainya jumlah perencanaan produksi pada bulan Oktober 2015 hingga Februari 2016, adanya breakdown mesin yang mengakibatkan pekerja harus lembur dan adanya defect produk yang mengakibatkan kerugian biaya yang cukup tinggi. Dalam penelitian ini kendala tersebut diselesaikan menggunakan pendekatan lean manufacturing Langkahlangkah penyelesaian dimulai dari mendeskripsikan proses produksi dengan menggunakan OPC dan VSM. Selanjutnya identifikasi waste kritis dengan metode Borda dan ditemukan tiga waste kritis yaitu waiting, defect dan motion. Dari ketiga waste tersebut kemudian diidentifikasi akar permasalahannya dengan RCA dan menentukan prioritas akar permasalahan dengan FMEA. Solusi perbaikan yang diusulkan antara lain menyeimbangkan penugasan dari lini penjahitan hingga packaging dengan menggunakan metode line balancing, modifikasi desain plat pada slide mesin trimming, membuat form pemeliharaan mesin extruder, dan menambahkan pengecekan ulang set up mesin extruder ke dalam SOP. Masingmasing alternatif solusi perbaikan dianalisis dengan benefit cost ratio. Berdasarkan perhitungan BCR keempat alternatif perbaikan memiliki ratio > 1 yang berarti solusi tersebut layak diterapkan di perusahaan. =========================================================== PT. Classic Automotive Manufacturing (PT. CAM) is one of car mats manufacturer in Surabaya. Their production process based on customer order. PT. CAM is the supplier of the car mats in seven distributors of automobile accessories in Japan. Their products are mostly shipped to Faltec America (FA) which is an automobile accessories distributor of Nissan Juke. In carrying out its production system PT.CAM having some problems such as fail to achieve the number of production planning in October 2015 until February 2016, breakdown machine which affect overtime works, and defects of products which affect high losses costs. That problems can be solved by using lean manufacturing approach. This research is conducted by describing the production process using OPC and VSM. The next step is identificating the critical waste with Borda method. Waiting, defects and motion are identified as critical waste. That critical waste will be identified the root causes by using RCA and the priority of root causes by using FMEA. The alternatives solutions that to be proposed are balancing the task from sewing lines until packaging lines, modificating the plates’s design of trimming machine’s slide, making maintenance form for extruder machine, and adding operational standard procedure (re-checking set up for extruder machine). The final step is calculating the cost of each alternative solution by using benefit cost ratio. Based on BCR results, all the alternative solutions have ratio>1, it means that the solutions is feasible.

Item Type: Thesis (Undergraduate)
Additional Information: RSI 658.5 Nur i
Uncontrolled Keywords: Benefit Cost Ratio, Lean manufacturing, Line balancing, OPC, VSM
Subjects: H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
Divisions: Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: EKO BUDI RAHARJO
Date Deposited: 02 Dec 2019 02:00
Last Modified: 02 Dec 2019 02:00
URI: https://repository.its.ac.id/id/eprint/72124

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