Optimalisasi Produksi Pipa Baja High Frequency Welding (HFW) dengan Cost Integrated Value Stream (CI-VS)

Ginting, Yasmin Nabilah (2021) Optimalisasi Produksi Pipa Baja High Frequency Welding (HFW) dengan Cost Integrated Value Stream (CI-VS). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Meningkatnya daya saing di pasar global memicu berbagai industri untuk mengembangkan sistem dan proses produksinya yang akan memberikan lebih banyak fleksibilitas, daya saing dan produk yang berkualitas tinggi. Waste merupakan salah satu kendala yang sering dihadapi oleh suatu perusahaan yang tidak hanya menghambat efisiensi produksi namun juga menyebabkan peningkatan pada biaya produksi yang harus dikeluarkan. Jika suatu perusahaan dapat menangani kendala dalam sistem produksi dengan baik, maka perusahaan tersebut akan memperoleh keuntungan yang lebih tinggi. Berdasarkan hal tersebut, Cost Integrated Value Stream (CI-VS) digunakan untuk memberikan gambaran pembebanan biaya berdasarkan aliran nilai aktivitas dan kerugian biaya atas pemborosan yang terjadi. Steel Pipe Industry (SPI) merupakan perusahaan manufaktur yang bergerak dalam produksi pembuatan dan pelapisan pipa baja untuk minyak dan gas dengan sistem produksi Engineering to Order (ETO). Pipa baja dengan las HFW merupakan salah satu produk yang dihasilkan oleh SPI. Pada proses produksi, terdapat pemborosan berupa waktu tunggu antar stasiun, terjadi pipa baja reject, dan penumpukan WIP pada lantai produksi. Peningkatan biaya produksi yang terjadi disebabkan oleh adanya baja reject yang memerlukan proses rework dan penumpukan material pipa di lantai produksi (WIP) yang menyebabkan peningkatan biaya inventory. Berdasarkan FMEA, waste dengan nilai RPN tertinggi terdapat pada waste defect pipa baja akibat reject stop start, serta terjadinya penumpukan WIP dan waiting karena perbedaan kecepatan proses pada mesin produksi. Berdasarkan hal tersebut, rekomendasi perbaikan terpilih yaitu pembuatan datasheet record parameter forming untuk meminimalisir waste defect dan penerapan kanban untuk mengurangi terjadinya penumpukan inventory dan terjadinya waiting. Berdasarkan penyusunan future state CI-VS, terdapat pengurangan waktu lead time sebesar 11168.15 menit, pengurangan biaya non-value-added sebesar Rp 4,030,862.65, pengurangan biaya inventory sebesar Rp 3,783,343.92, pengurangan biaya rework sebesar Rp 247,513.73, dan pengurangan rejection cost sebesar Rp 233,628,534.15. ===================================================================================================== Increased competitiveness in the global market triggers various industries to develop production systems and processes that will provide more flexibility, competitiveness, and high-quality products. Waste is one of the obstacles that a company often faces, which hampers production efficiency and causes an increase in production costs. If a company can handle the constraints in the production system well, then the company will get higher profits. Based on this, the Cost Integrated Value Stream (CI-VS) provides an overview of the cost assignment based on the flow of activity values and cost losses for the waste that occurs. Steel Pipe Industry (SPI) is a manufacturing company engaged in manufacturing and coating steel pipes for oil and gas with an Engineering to Order (ETO) production system. HFW welded steel pipe is one of the products produced by SPI. There is waste in waiting time between stations, reject steel pipes, and the buildup of WIP on the production floor in the production process. The increase in production costs caused by the presence of reject steel required a rework process and the accumulation of pipe material on the production floor (WIP), which led to an increase in inventory costs. Based on FMEA, the waste with the highest RPN value is in the steel pipe defect waste due to reject stop-start, the accumulation of WIP, and waiting due to differences in processing speed on the production machine. Based on this, the selected improvement recommendations make datasheet record parameters forming to minimize defect waste and implement kanban to reduce inventory buildup and waiting. Based on the preparation of the CI-VS future state, there is a reduction in the lead time of 11168.15 minutes, a reduction in non-value-added costs of Rp. 4,030,862.65, a reduction in inventory costs of Rp 3,783,348.92, a reduction in rework costs of Rp 247,513.73, and a reduction in rejection costs of Rp 233,628,534.15.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Industri Pipa Baja, Waste, Continuous Improvement, Cost Integrated Value Stream (CI-VS), Theory of Constraint (TOC), Lean Manufacturing, Steel Pipe Industry,
Subjects: T Technology > TS Manufactures
T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
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: Yasmin Nabilah Ginting
Date Deposited: 26 Jul 2021 07:53
Last Modified: 26 Jul 2021 08:58
URI: https://repository.its.ac.id/id/eprint/84475

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