scholarly journals Aplikasi Konsep Produksi Ramping untuk Memperbaiki Efisiensi Pengolahan Minyak Kelapa Sawit

2018 ◽  
Vol 11 (2) ◽  
pp. 36
Author(s):  
Adriansyah Adriansyah ◽  
Agus Sutanto ◽  
Berry Yuliandra
Keyword(s):  
Lean Manufacturing ◽  
Fresh Fruit ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Average Score ◽  
Total Production ◽  
Processing Efficiency ◽  
Palm Fruit ◽  
Value Stream ◽  
Fresh Fruit Bunches

Manfaat dari penelitian ini adalah untuk menerapkan konsep produksi ramping (lean manufacturing) pada proses pengolahan minyak kelapa sawit sehingga pemborosan yang terjadi dapat diidentifikasi serta diminimasi. Identifikasi pemborosan dilakukan melalui pengamatan dan kuesioner. Hasil identifikasi dengan menggunakan kuesioner digunakan sebagai dasar untuk menentukan alat pemetaan VALSAT yang sesuai untuk digunakan dalam analisis. Identifikasi pemborosan dengan kuesioner menunjukkan bahwa stasiun yang banyak menghasilkan pemborosan adalah loading ramp dan sterilizer. Berdasarkan konsep produksi ramping, pemborosan pada pengolahan CPO berdasarkan urutan tertinggi adalah ini adalah aktivitas menunggu, diikuti oleh transportasi dan gerakan berlebih, proses yang tidak diinginkan dan kecacatan bahan baku. Berdasarkan Value Stream Mapping (VSM) kondisi saat ini diketahui bahwa total waktu pengolahan CPO adalah 32700 detik serta efisiensi pengolahan CPO sebesar 30,7%. Kapasitas pengolahan sebesar 40 ton TBS/jam dan operator berjumlah sebanyak 26 operator. Rancangan perbaikan yang diusulkan dapat menurunkan total waktu produksi menjadi 23472 detik sekaligus memperbaiki efisiensi pengolahan menjadi 35,6% dengan kapasitas olah menjadi 55 ton TBS/jam dan dengan pengurangan operator hingga 5 orang. The objective of this research is to implement  the concept of lean manufacturing in the oil palm fruit processing, so the wastes that commonly occur can be identified and minimized. The identification method of wastes is done through the observations and questionnaires. The result of identification by questionnaires was applied to determine the appropriate VALSAT mapping tool used in analysis. Identification of waste by using questionnaires shows that the wasteful stations are loading ramp and sterilizer. Based on lean concept, the overall wastes occured in CPO processing are waiting with an highest average score,and then followed by excessive transportation and movements, unexpected processing and defects of the raw material. Based on Value Stream Mapping (VSM) of the current condition is known,that the total processing time of CPO is 32700 second with processing efficiency equal to 30,7%.The capacity is 40 tons of fresh fruit bunches per hour with 26 operators. The proposed improvement plan can reduce the total production time up to 23472 seconds while increasing processing efficiency to 35.6% with capacity to 55 tons of fresh fruit bunches per hour and with operator reduction up to 5 people.

scholarly journals Penerapan Lean Manufacturing dengan Metode VSM dan FMEA untuk Mereduksi Pemborosan Produksi Sarden

2020 ◽  
Vol 13 (1) ◽  
Author(s):  
Haris Dwi Armyanto ◽  
Dwi Djumhariyanto ◽  
Santoso Mulyadi
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Waiting Time ◽  
Lean Manufacturing ◽  
Waiting Times ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Current State

CV.X merupakan salah satu perusahaan pengolahan sarden yang terletak di Banyuwangi. Pada proses produksi di perusahaan masih ditemukan beberapa pemborosan (waste). Untuk mengurangi pemborosan yang terjadi digunakan pendekatan lean manufacturing dengan metode Value Stream Mapping (VSM) untuk pemetaan aliran produksi dan aliran informasi terhadap proses produksi dari awal bahan baku hingga produk jadi dan dikirim ke konsumen, serta analisis dengan metode Failure Mode and Effects Analysis (FMEA) untuk mengetahui penyebab kegagalan proses yang paling prioritas dan perlu dilakukan perbaikan dengan segera. Identifikasi pemborosan diawali dengan penggambaran current state map, lalu dilakukan analisis pemborosan ke dalam kategori 7 pemborosan [1]. Pada analsis tersebut ditemukan 3 jenis pemborosan yaitu waiting time, unnecessary inventory dan defect (kembung). Setelah itu dilakukan analisis akar penyebab timbulnya pemborosan menggunakan fishbone diagram, dan analis FMEA untuk mengetahui nilai RPN tertinggi yang selanjutnya akan menjadi prioritas pemberian usulan perbaikan yang tepat dan sesuai dengan masalah dan kondisi proses produksi sarden 125g di CV.X. Rekomendasi perbaikan yang diberikan terhadap pemborosan dengan nilai RPN tertinggi antara lain Menambahkan mesin pencuci produk untuk mengurangi penumpukan produk dan waktu tunggu yang ada sehingga pemborosan waiting time dan unnecessary inventory dapat berkurang, mengganti sarung tangan kain dengan lateks, serta menjaga kebersihan nampan ikan. CV.X is a sardine processing company located in Banyuwangi. In the company production process there are some wastes. To reduce the waste that occurs, lean manufacturing approach using Value Stream Mapping (VSM) method is used to map the production flow and information flow to the production process from the beginning of the raw material to the finished product and sent to consumers, as well as analysis using the Failure Mode and Effects Analysis (FMEA) method. ) to find out what causes the most priority process failures and needs immediate improvement. Waste identification is preceded by a depiction of the current state map, then waste analysis is conducted into category 7 waste. In this analysis, there are 3 types of waste, which are waiting time, unnecessary inventory and defects. After that an analysis of the root causes of waste occurs using fishbone diagrams, and FMEA analysts to find out the highest RPN value which will then be prioritized for giving recommendations for an appropriate improvement and in accordance with the problems and conditions of the 125g sardine production process in CV.X. Improvement recommendations given for waste with the highest RPN value include adding a product washer to reduce product buildup and waiting times so that waiting time and unnecessary inventory waste can be reduced, replacing cloth gloves with latex, and keeping the fish tray clean.

Lean Manufacturing Implementation Through Value Stream Mapping: A Case Study

2014 ◽  
Vol 68 (3) ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Ahmad Hashemi ◽  
Ahmed Ali Abdi ◽  
Ataollah Shahpanah ◽  
Jafri Mohd Rohani
Keyword(s):  
Business Strategy ◽  
Production Line ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Secondary Data ◽  
Value Stream Mapping ◽  
Total Production ◽  
Value Stream ◽  
Value Stream Map

Lean Manufacturing (LM) is a business strategy that was developed in Japan. The main contribution of lean manufacturing is the identification and elimination of waste. Companies apply LM to sustain their competitiveness over their competitors by improving the manufacturing system’s productivity and quality enhancement of the product. The goal of this paper is to apply one of the most significant lean manufacturing techniques called Value Stream Mapping (VSM) to improve the production line of a company that produces several components for vehicle assembly line by decreasing the waste and non-value added activities.  First, the current value stream map of production line was developed using personal interviews, observations and secondary data of the company. Subsequently, the future value stream map was proposed based on the lean manufacturing principles to improve total production lead time and value added time. Based on the final result it can be concluded that VSM is a useful and applicable approach that can help managers conceptualize the different kind of wastes and defects. Final result showed that the production lead time and value added time improved up to nearly 80 % and 12 % respectively by eliminating the wastes based on lean principles and VMS method. 

scholarly journals Variability and Uncertainty Analysis in Value Stream Mapping

2019 ◽  
Vol 8 (12S2) ◽  
pp. 533-538
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Strong Impact ◽  
Food Sector ◽  
Value Stream ◽  
Current State ◽  
Potential Risks ◽  
Tools And Techniques ◽  
A Current

Lately, value stream mapping (VSM) is integrated with tools and techniques that belong to other areas of knowledge such as risk management (RM). It is well known tool in showing the value, value stream and the flow which represents three of lean manufacturing (LM) principles. This integration, gives more benefit in covering two of VSM issues such as considering the variability and uncertainty of production processes. In this paper, a model named variable value stream mapping (V-VSM) that integrates the two was showed, explained and tested. The model helps to generate the VSM in a dynamic way with the identification of current and potential risks. These risks might happen in the future bringing a strong impact on not reaching the main objectives in the defined time and cost. The model has been tested by conducting a case study in food sector. A current state map was built using both models, traditional VSM and VVSM. The results showed the effect of variability and uncertainty on the total cycle time (CT) and lead time (LT) values, where the traditional VSM failed to show it by being a static tool. Comparing the results of both models show the differences in presenting the real state of manufacturing environment..

scholarly journals Production flow improvement and value stream mapping in a lean manufacturing world

2021 ◽  
Vol 6 (1) ◽  
pp. 036-050
Author(s):  
Muhammad Adib Uz Zaman ◽  
Emad Rabiei Hosseinabad
Keyword(s):  
Lean Manufacturing ◽  
Performance Metrics ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Assembly Simulation ◽  
Kaizen Events ◽  
Load Leveling ◽  
And Performance ◽  
Flow Improvement

The importance of lean manufacturing concepts has been discussed many times over the few decades. The most important elements in lean manufacturing practices are value stream mapping (VSM), Kaizen events, load leveling (heijunka), etc. In this case study, a real-world clock assembly simulation has been used to study the performance improvement in terms of production flow and lead time after introducing lean concepts. In each round of simulation, the lean concepts have been introduced one by one and performance metrics were recorded. After implementing the concepts, the productivity was improved enormously. So, this simulation study emphasizes the importance of continuous improvement of production flow through lean concepts in a real production setting.

scholarly journals ANALISIS PEMBOROSAN PRODUKSI PADA ALIRAN PRODUK JALA IKAN KKP MENGGUNAKAN PRINSIP LEAN MANUFACTURING DENGAN METODE VALUE STREAM MAPPING (VSM) DI PT. INDONEPTUNE NET MANUFACTURING

2019 ◽  
Vol 7 (2) ◽  
pp. 79-89
Author(s):  
Henny Henny ◽  
Muhammad Kahfi Hadi Syuhada
Keyword(s):  
Cycle Time ◽  
Delay Time ◽  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Time Level ◽  
Value Stream ◽  
Current State

  Penelitian ini ditujukan untuk menganalisis pemborosan produksi produk Jala Ikan KKP menggunakan lean manufacturing di PT. Indoneptune Net Manufacturing dengan memetakan aliran produksi dan menganalisisnya menggunakan value stream mapping (VSM). Analisis terhadap pemborosan dengan metode VSM dilakukan karena VSM dapat memetakan aliran informasi dan material dari awal sampai akhir dari value stream pembuatan suatu produk. Sehingga dapat dilihat proses mana saja yang merupakan pemborosan. Adapun VSM yang dibuat adalah current-state VSM karena dapat merepresentasikan kondisi saat ini dari aliran produksi yang ada. Hasil yang didapatkan setelah dibuat current-state VSM adalah aliran produksi produk jala Ikan KKP melewati proses spinning, ring roupe, netting dan finishing yang memiliki sub-sub proses yang berbeda. Dari setiap sub-proses tersebut dipetakan nama proses, jumlah waktu cycle time dan changeover time, level inventory, waktu kerja tersedia dan jumlah operator. Penganalisisan pemborosan dilakukan pada setiap sub-proses untuk dapat mengetahui nilai tambah proses tersebut terhadap produk utama yang sedang dikerjakan pada setiap tahapan proses yang berlangsung. Kesimpulan yang didapat yaitu pemborosan yang terjadi di departemen spinning salah satunya adalah delay time karena persiapan sebelum proses peleburan, waktu tunggu karena persiapan proses twist di departemen ring roupe, transportasi berlebih sebelum proses tatekan dan pengerjaan ulang di hoshu 2 di departemen finishing.

scholarly journals Energy Analysis via Value Stream Mapping: A case study of an Automotive Weld Plant

ORiON ◽  
2021 ◽  
Vol 37 (2) ◽  
Author(s):  
Keshav Ramsunder ◽  
Oludolapo Olanrewaju
Keyword(s):  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Measuring Instruments ◽  
Manufacturing Companies ◽  
Step Method ◽  
Empirical Observation ◽  
Value Stream ◽  
Starting Point

Over the past few decades, Lean Manufacturing (LM) has been the pinnacle of strategies applied for cost and waste reduction. However as the search for competitive advantage and production growth continues, there is a growing consciousness towards environmental preservation. With this consideration in mind this research investigates and applies Value Stream Mapping (VSM) techniques to aid in reducing environmental impacts of manufacturing companies. The research is based on empirical observation within the Chassis weld plant of Company X. The observation focuses on the weld operations and utilizes the cross member line of Auxiliary Cross as a point of study. Using various measuring instruments to capture the emissions emitted by the weld and service equipment, data is collected. The data is thereafter visualised via an Environmental Value Stream Map (EVSM) using a 7-step method. It was found that the total lead-time to build an Auxiliary Cross equates to 16.70 minutes and during this process is emitted. It was additionally found that the UPR x LWR stage of the process indicated both the highest cycle time and carbon emissions emitted and provides a starting point for investigation on emission reduction activity. The EVSM aids in the development of a method that allows quick and comprehensive analysis of energy and material flows. The results of this research are important to practitioners and academics as it provides an extension and further capability of Lean Manufacturing tools. Additionally, the EVSM provides a gateway into realising environmental benefits and sustainable manufacturing through Lean Manufacturing.

scholarly journals MEMINIMASI PEMBOROSAN DENGAN LEAN MANUFACTURING PADA PROSES PRODUKSI DI PT. IE

2021 ◽  
pp. 1451
Author(s):  
Ahmad Ahmad ◽  
Helena JK ◽  
Andrean Yonathan
Keyword(s):  
Waiting Time ◽  
Cycle Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Fault Tree Analysis ◽  
Value Stream Mapping ◽  
Tree Analysis ◽  
Value Stream ◽  
Current State ◽  
Future State

PT. IE is engaged in the business of making Lighting and Lampposts. Based on observations and interviews, there are still some wastes that arise in the flow of the production process, among which there are still many wastes of waiting time, transportation, movement and inventory. These wastes cause the product completion time to be longer and the resulting quality decreases. To eliminate or reduce waste, it is necessary to apply Lean Manufacturing. Lean Manufacturing is a systematic approach to eliminating waste and changing processes by identifying and reducing waste with continuous improvement and striving to create a production flow along the value stream by eliminating all forms of waste and increasing the added value of products to customers. From the Pareto diagram, it is found that transportation waste has the highest percentage of 26.21%, waiting time is 21.38%, motion waste is 19.31% and waste inventories are 15.17%. while the results of the Value Stream Mapping Current State Map mapping obtained a production lead time of 7,680 seconds and a total cycle time of 6,660 seconds and a PCE Current State Map value of 53.09%. Identify the root causes of waste using Fishbone diagrams, 5 Why Analysis, 5W+1H, Fault Tree Analysis and FMEA. After corrective actions have been taken, based on the Value Stream Mapping Future mapping there is a decrease in production lead time to 5,220 seconds and a decrease in total cycle time to 4,860 seconds and an increase in PCE Future State Map to 68.10% so that there is an increase of 15.01% which shows The company's production process has become more Lean.PT. IE bergerak dalam bisnis pembuatan Lighting dan Tiang Lampu. Berdasarkan observasi dan wawancara, masih terdapat beberapa pemborosan (waste) yang timbul di aliran proses produksi di antaranya masih banyak terjadi pemborosan-pemborosan waktu tunggu, transportasi, gerakan dan inventori. Pemborosan-pemborosan tersebut menyebabkan waktu penyelesaian produk menjadi lebih lama dan kualitas yang dihasilkan menurun. Untuk menghilangkan atau mengurangi pemborosan diperlukan adanya penerapan Lean Manufacturing.Lean Manufacturing merupakan pendekatan sistematik untuk mengeliminasi pemborosan dan mengubah proses dengan cara mengidentifikasi dan mengurangi pemborosan dengan perbaikan kontinu dan berupaya untuk menciptakan aliran produksi sepanjang value stream dengan menghilangkan segala bentuk pemborosan serta meningkatkan nilai tambah produk kepada pelanggan. Dari diagram Pareto ditemukan waste transportasi memiliki persentase paling tinggi sebesar 26,21%, waktu tunggu  21,38%, waste motion 19,31% dan waste inventories 15,17%. sedangkan hasil pemetaan Value Stream Mapping Current State Map diperoleh production lead time selama 7.680 detik dan total cycle time selama 6.660 detik serta nilai PCE Current State Map sebesar 53,09%. Identifikasi akar permasalahan pemborosan menggunakan diagram Fishbone, 5 Why Analysis, 5W+1H, Fault Tree Analysis dan FMEA. Setelah dilakukan tindakan–tindakan perbaikan, berdasarkan pemetaan Value Stream Mapping Future ada penurunan production lead time menjadi 5.220 detik dan penurunan total cycle time menjadi 4.860 detik serta ada peningkatan PCE Future State Map menjadi 68,10% sehingga ada peningkatan 15,01% yang menunjukan proses produksi perusahaan telah menjadi lebih Lean.

Sign in / Sign up

Export Citation Format

Share Document