Perbaikan Proses Produksi Jerrycan 5 Liter di PT. KEMASAN Menggunakan Pendekatan Lean Manufacturing

Pontiana, Aisyah (2020) Perbaikan Proses Produksi Jerrycan 5 Liter di PT. KEMASAN Menggunakan Pendekatan Lean Manufacturing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. KEMASAN adalah perusahaan manufaktur yang bergerak dalam produksi packaging plastik. Produk jerrycan 5 liter merupakan produk yang paling banyak dipesan oleh customer VVIP dan diproduksi secara kontinu. Pada kondisi aktual perusahaan terdapat permasalahan yang dapat menurunkan kepuasan pelanggan dilihat dari complain berupa ketidaksesuaian produk yang diterima customer, produk defect melebihi standar 3%, persentase breakdown mesin melebihi standar 2.5%, dan adanya keterlambatan pengiriman produk jerrycan 5 liter sebanyak sembilan kali pada tahun 2019. Timbulnya permasalahan tersebut dapat menurukan kepercayaan konsumen dan bahkan menyebabkan kerugian finansial. Adanya defect dan breakdown merupakan indikasi pemborosan pada proses produksi. Oleh karena itu penelitian ini dilakukan untuk mengurangi pemborosan dengan pendekatan lean manufacturing. Penelitian dimulai dari identifikasi proses produksi dan waste menggunakan tools value stream mapping, process activity mapping, observasi, dan diskusi dengan pihak expert perusahaan. Kemudian dilakukan penentuan waste kritis dengan metode Borda dan didapatkan hasil waste kritis yaitu waste defect dan waste unnecessary motion. Selanjutnya dilakukan analisis akar penyebab waste kritis dengan menggunakan metode 5 whys dan dilakukan penentuan kategori risiko dengan pengisian kuisioner FMEA untuk menilai severity, occurrence, dan detection dari setiap akar permasalahan. Dalam penelitian ini diusulkan 3 alternatif perbaikan dan kombinasinya untuk kemudian dilipih alternatif terbaik menggunakan pendekatan value analysis berdasarkan pada performansi dan biayanya. Kombinasi alternatif terbaik terpilih yaitu membuat checklist perawatan komponen, membuat standar pengambilan sampel susuai military standard, menambah jumlah pengawas teknik dalam satu shift, menerapkan 5S, menyediakan pijakan tangga, dan menempelkan SOP pada area kerja yang terlihat oleh operator. Dengan penerapan alternatif tersebut dihasilkan future state value stream mapping dengan penurunan lead time dari 3058 detik menjadi 2898 detik dan nilai value added bertambah sebanyak 1.2%.
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PT. KEMASAN is a manufacturing company engaged in the production of plastic packaging. 5-liter jerrycan is the most ordered products by VVIP customers and produced continuously. In the actual condition, there are some problems that can reduce customer satisfaction as seen from complaints from customer, product defects exceeding the standard 3%, the engine breakdown percentage exceeds the standard 2.5%, and there were nine times delays in the delivery of 5-liter jerrycan in 2019. The emergence of these problems could reduce consumer’s trust and even cause financial losses. The existence of defects and breakdowns is an indication of waste in the production process. Therefore this research was conducted to reduce waste by lean manufacturing approach. The research starts from identifying the production process and identifying waste using value stream mapping tools, process activity mapping, observation, and discussion with company experts. Then the critical waste determination is done by Borda method and the results of critical waste are defect and unnecessary motion waste. After that, the root cause of critical waste is analyzed using the 5 whys method and risk number determine by FMEA questionnaire to assess the severity, occurrence, and detection of each root problem. In this study, three alternative improvements and combinations are proposed, and then the best alternative choosen from value analysis approach based on performance and cost of improvement. The best alternative combination selected is making a component checklist, making a standard military military sampling, increasing the number of technical supervisors in one shift, implementing 5S, providing a stepping ladder, and attaching SOP to the visible work area. With the implementation of these alternatives, the future state value stream mapping is generated with a reduction in lead time from 3058 seconds to 2898 seconds and the value added increases by 1.2%.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Lean Manufacturing, Value Stream Mapping, Process Activity Mapping, Borda Voting Method, 5 Whys, Failure Mode and Effect Analysis, Value Analysis
Subjects: T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: Aisyah Pontiana
Date Deposited: 21 Aug 2020 01:26
Last Modified: 21 Aug 2020 01:26
URI: http://repository.its.ac.id/id/eprint/79273

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