Alfarizky, Yunazzilul (2021) Implementasi Konsep Lean Pada Proses Changeover Industri Pakan Ikan. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT.CI merupakan perusahaan multinasional produksi pakan ikan yang menggunakan Overall Equipment Efficiency(OEE) sebagai indikator efisiensi proses produksi secara keseluruhan. Penelitian ini membahas mesin Extruder 2 yang memiliki nilai rata-rata OEE paling rendah yaitu 65% dimana losses terbesar terdapat pada availability yaitu 22% karena seringnya melakukan changeover. Aktivitas changeover menghilangkan waktu produksi sebesar 58.2 jam atau setara dengan 247 ton produk dalam satu bulan. Process Activity Mapping dan Spaghetti diagram digunakan untuk identifikasi waste pada proses changeover, Root Cause Analysis menggunakan 5 why’s untuk mencari akar permasalahan terjadinya waste, Single Minutes Exchanges of Dies untuk mereduksi waktu setup produksi, 5S dan Spaghetti diagram untuk menciptakan area kerja yang rapi, bersih dan produktif, Standar Operational Procedure, Visual Management dan Pelatihan diperlukan untuk meningkatkan perfoma kerja Operator dan Helper, Impact & Effort matrix untuk menentukan rekomendasi solusi dan dimana Quick Wins adalah prioritas utama, Implikasi Manajerial untuk mejalankan rekomendasi solusi. SMED dapat menghemat waktu changeover keseluruhan sebesar 45,1% untuk changeover size dan 42,5% untuk changeover formula. 5S dan Spaghetti diagram dapat menghemat waktu aktifitas setup external 54%. Standar Operational Procedure, Visual Management dan Pelatihan Operator dan Helper dapat menghemat waktu aktifitas setup external 25%. Estimasi kenaikan OEE setelah melakukan rekomendasi solusi adalah 14%.
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PT.CI is a multinational fish feed production company that uses Overall
Equipment Efficiency (OEE) as an indicator of the efficiency of the overall
production process. This study discusses the Extruder 2 machine which has the
lowest average OEE value of 65% where the biggest losses are in availability,
which is 22% due to frequent changeovers. The changeover activity eliminates
production time by 58.2 hours or equivalent to 247 tons of product in one month.
Process Activity Mapping and Spaghetti diagrams are used to identify waste in
the changeover process, Root Cause Analysis uses 5 why's to find the root cause
of waste occurrence, Single Minutes Exchanges of Dies to reduce production
setup time, 5S and Spaghetti diagrams to create a neat, clean work area and
productive, Standard Operational Procedure, Visual Management and Training are
needed to improve the work performance of Operators and Helpers, Impact &
Effort matrix to determine solution recommendations and where Quick Wins is
the top priority, Managerial Implications to implement solution recommendations.
SMED can save 45.1% overall changeover time for size changeover and 42.5%
for formula changeover. 5S and Spaghetti diagrams can save 54% external setup
activity time. Standard Operational Procedure, Visual Management and Operator
and Helper Training can save 25% external setup activity time. The estimated
increase in OEE after making recommendations for solutions is 14%.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | 5S, 5 why’s, Impact & Effort matrix, Lean, Process Activity Mapping, Root Cause Analysis, Single Minutes Exchanges of Dies, Spaghetti diagram, Standar Operational Procedure, Training, Visual Management, 5 why’s, Impact & Effort matrix, Lean, Process Activity Mapping, Root Cause Analysis, Single Minutes Exchanges of Dies, Spaghetti diagram, Standar Operational Procedure, Training, Visual Management |
| Subjects: | T Technology > T Technology (General) > T58.8 Productivity. Efficiency |
| Divisions: | Faculty of Creative Design and Digital Business (CREABIZ) > Technology Management > 61101-(S2) Master Thesis |
| Depositing User: | Yunazzilul Al Farizky |
| Date Deposited: | 22 Aug 2021 21:53 |
| Last Modified: | 22 Aug 2021 21:53 |
| URI: | http://repository.its.ac.id/id/eprint/89396 |
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