Abstrak-CV. ABC Offset adalah sebuah perusahaan yang bergerak dibidang percetakan dengan sistem make to order, dimana salah satu produk yang konsisten dipesan adalah hanger sample yang dipesan oleh perusahaan tekstil. Pada bulan Januari, Februari, Juni, Agustus, dan Oktober produksi tidak mencapai jumlah permintaan (73%, 80%, 92%, 71%, dan 50%). Hal tersebut disebabkan oleh permasalahan yang menghambat jalannya proses produksi. Melalui hasil observasi lapangan dan hasil pengolahan kuesioner, diketahui bahwa salah satu waste dominan yang terjadi pada proses pembuatan hanger sample adalah waste waiting. Upaya meminimasi waste waiting pada penelitian ini dilakukan dengan menggunakan pendekatan lean manufacturing. Penelitian diawali dengan melakukan pengumpulan data, seperti alur proses produksi, waktu siklus, kuesioner, data permintaan, data produksi, data jumlah operator, dan data jam kerja. Selanjutnya dilakukan pemetaan aliran proses saat ini dengan menggunakan value stream mapping (VSM) dan process activity mapping (PAM) current state. Tahap berikutnya adalah mengidentifikasi akar penyebab waste waiting dengan menggunakan diagram fishbone, diagram pareto, dan 5 whys. Setelah diketahui akar penyebabnya, dibuat usulan perbaikan guna meminimasi waste waiting dimana bidang ilmu yang akan digunakan adalah perancangan tata letak fasilitas. Setelah itu value stream mapping (VSM) future state dibuat untuk memetakan perbaikan yang akan diusulkan. Kata kunci: lean manufacturing, value stream mapping, process activity mapping, waste waiting, perancangan tata letak fasilitasAbstract-CV. ABC Offset is a printing company with make to order system, which hanger sample is a product being ordered constantly by textile companies. In January, February, June, August and October the amount production did not reach the demand (73%, 80%, 92%, 71%, dan 50%). It was due to the problem that inhibit production. Based on field observation and questionnaire data processing, it was known that one of dominant waste occured in the production process of hanger sample was waste waiting. Effort to minimize the waste in this research will be done with lean manufacturing approach. The research will be started by collecting data, such as production process flow, cycle time, questionnaire, demand data, production data, number of operators and work hour. After that, value stream mapping (VSM) and process activity mapping (PAM) current state will be made for mapping the process flow. The next step is identifying the root cause of waste waiting using fishbone diagram, pareto diagram and 5 whys. After the root cause is known, the proposed improvement is made to minimize waste waiting where the subject that will be used is facility layout planning. Then, value stream mapping (VSM) future state will be made for mapping the flow process and improvements that will be proposed.
CV. Gradient merupakan perusahaan manufaktur yang memproduksi plastik menggunakan mesin injection molding. Produk pada penelitian ini fokus pada produk spring guide dengan tipe XXX. Berdasarkan hasil observasi, wawancara dan kuesioner terdapat beberapa waste yang ditemukan dalam proses produksinya, salah satunya adalah waste yang menjadi fokus penelitian yaitu waste waiting time. Metode untuk meminimasi waste tersebut adalah dengan menggunakan konsep lean manufacturing. Penelitian dimulai dengan melakukan observasi dan wawancara untuk memperoleh data-data yang menunjang pemetaan proses produksi spring guide yang terjadi dengan menggunakan value stream mapping (VSM) dan process activity mapping (PAM) sehingga diketahui total waktu non-value added akibat waste waiting time adalah 7161.87 detik atau 57.8% dari lead time. Setelah itu, dilakukan analisis akar penyebab waste waiting time dengan menggunakan 5 whys dan fishbone diagram. Hasil dari analisis akar penyebab waste dapat digunakan untuk menentukan usulan rancangan yang akan dibuat berupa jadwal pemeliharaan mesin injection molding menggunakan preventive maintenance untuk mengurangi aktivitas non-value added. Pada kondisi yang akan datang, usulan rancangan dapat menghilangkan waktu menunggu dan waktu perbaikan yang menyebabkan waste waiting time. Berdasarkan future state total waktu non-value added dapat dikurangi menjadi 721.87 detik atau 12.12% dari lead time yang diperoleh dari penghilangan aktivitas menunggu dan aktivitas perbaikan.
is a manufacturing company that produces water meters. In producing water meters, one of the parts is the head casing. Head casing part consists of two types namely LF-1 and LF-2. Constraints experienced by companies are the inaccessibility of head casing production targets that can hinder the sale of water meters to consumers. For this reason, a proposal to improve the lean manufacturing approach is proposed to minimize the waste that occurs. The stage of the lean manufacturing approach is to identify the production process that occurs using the Process Activity Mapping and Value Stream Mapping. Furthermore, identifying waste that occurs using fishbone diagrams. After identifying waste, waste motion is found in the process of making the head casing part with manual lathes. Subsequently, proposed improvements were made using the Single Minutes Exchange of Die (SMED) method. After the proposed improvement, the company's profitability can be calculated by comparing the existing production costs after the proposed improvements.
is a manufacturing company that produces water meters. In producing water meters, one of the parts is the head casing. Head casing part consist of two types namely LF-1 and LF-2. Constraints experienced by companies are the inaccessibility of head casing production targets that can hinder the sale of water meters to consumers. For this reason, a proposal to improve the lean manufacturing approach is proposed to minimize the waste that occurs. The stage of the lean manufacturing approach is to identify the production process that occurs using the Process Activity Mapping and Value Stream Mapping. Furthermore, identifying waste that occurs using fishbone diagrams. After identifying waste, waste motion is found in the process of making head casing part with manual lathes. Subsequently, proposed improvements were made using the Single Minutes Exchange of Die (SMED) method. After the proposed improvement, in one month the company can save production costs of Rp 24.000.000 by comparing the existing production costs with after the proposed improvements.
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