Reduksi Waste Pada Proses Produksi Pasta Gigi Pt. X Dengan Konsep Lean Production Dan Benefit Cost Ratio

Nugroho, Joshua Triputro (2016) Reduksi Waste Pada Proses Produksi Pasta Gigi Pt. X Dengan Konsep Lean Production Dan Benefit Cost Ratio. Undergraduate thesis, Institut Teknologi Sepuluh Nopember Surabaya.

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Abstract

PT.X merupakan salah satu perusahaan Fast Moving Consumer Goods (FMCG) terkemuka di Indonesia yang berdiri sejak tahun 1933. Beberapa produk unggulan PT. X adalah Pasta Gigi P dan Pasta Gigi CU. Hal ini dibuktikan dengan besarnya jumlah rata-rata market share kedua produk ini, yaitu 85,56% selama tahun 2008-2010. Namun, terdapat permasalahan pada proses produksi kedua produk tersebut. Hal ini dibuktikan dengan tidak tercapainya target output rate beberapa varian dari kedua produk tersebut selama bulan Januari hingga Maret 2016, yaitu dengan rata-rata 93,53% dari target perusahaan 96%. Hal ini terjadi karena diindikasikan adanya pemborosan (waste) pada lantai produksi seperti hasil pasta gigi yang defect dan adanya bottleneck pada proses pengemasan. Oleh karena itu, diperlukan penerapan konsep lean production untuk mereduksi waste tersebut. Penelitian ini dilakukan pada varian produk Pasta Gigi P White dan Pasta Gigi CU Green karena tingginya permintaan pada 2 jenis produk ini. Penelitian ini dimulai dengan mengidentifikasi waste kritis menggunakan metode Value Stream Mapping (VSM) dan Borda Count Method (BCM). Waste kritis yang didapatkan yaitu waste defect, waiting, dan inventory. Setelah didapatkan waste kritis, selanjutnya dilakukan analisis akar penyebab permasalahan waste kritis tersebut dengan Root Cause Analysis (RCA) menggunakan teknik 5 Why’s dan Failure Mode and Effect Analysis (FMEA) untuk mengetahui root cause dengan prioritas tertinggi. Setelah didapatkan root cause dengan prioritas tertinggi, diberikan rekomendasi perbaikan dan dilakukan analisis Benefit Cost Ratio (BCR). Berdasarkan hasil analisis dan perhitungan, didapatkan 3 rekomendasi perbaikan yaitu pembuatan standard operational procedure (SOP) yang melibatkan proses kalibrasi dan pembersihan dengan nilai BCR sebesar 1,44 untuk waste defect, pengadaan safety stock untuk packaging material dengan nilai BCR sebesar 1,15 untuk waste waiting, dan pengadaan pallet rack untuk pallet hasil racikan pada area processing dengan nilai BCR sebesar 1,67 untuk waste inventory. Karena ketiga rekomendasi perbaikan ini bernilai lebih dari 1, maka seluruh rekomendasi perbaikan layak dilakukan. Dengan rekomendasi ini, diharapkan output rate produksi dapat meningkat dan mencapai target perusahaan. ============================================================ PT. X is one of the top Fast Moving Consumer Goods (FMCG) manufacturer in Indonesia that established since 1933. Some of the superior products in PT. X are P White Toothpaste and CU Green Toothpaste. It is proven by the large number of market share from these two products with an average 85.56% during 2008-2010. However, there are some problems in the production process of these products. It is proven by several variants from these two products were not achieving the company’s output rate target during January to March 2016, which is only having an average 93.53% out of 96% from the company's target. This problem occurs due to the indication of waste on the production floor such as toothpase defect and bottleneck at the packing line. Therefore, it needs to apply the concept of lean production to reduce waste. Research was conducted on the product variant P White Toothpaste and CU Green Toothpaste because of the high demand on these two types of products. The research started by identifying critical waste using Value Stream Mapping (VSM) and the Borda Count Method (BCM). Earned critical waste are defect, waiting, and inventory. After knowing the critical waste, Root Cause Analysis (RCA) is conducted by using 5 Why's technique and Failure Mode and Effect Analysis (FMEA) to determine the root cause with the highest priority. After obtaining the root cause with highest priority, improvement recommendations are given and analyzed by using Benefit Cost Ratio (BCR). Based on the analysis and calculation, it is obtained three recommendations for improvement, such as Standard Operational Procedure (SOP) which involves the process of calibration and cleaning with BCR value 1.44 for the defect waste, safety stock for packaging material with BCR value 1.15 for waiting waste, and procurement of pallet rack for pallet concoction in the processing area with BCR value 1.67 for the inventory waste. As BCR value of these given recommendations are more than 1, then all recommendations are feasible to be done. With this recommendations, the production output rate will be expected to increase and reach the company’s target.

Item Type: Thesis (Undergraduate)
Additional Information: RSI 658.5 Nug r
Uncontrolled Keywords: Benefit Cost Ratio, Borda Count Method, Failure Mode and Effect Analysis, Lean Production, Root Cause Analysis, VSM, Waste
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: 03 Jan 2020 06:32
Last Modified: 03 Jan 2020 06:32
URI: https://repository.its.ac.id/id/eprint/72516

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