ANALISIS PENERAPAN KONSEP LEAN MANUFACTURING PADA PROSES PRODUKSI STAINLESS STEEL COIL UNTUK MEREDUKSI PEMBOROSAN (WASTE) DI PT. XYZ

PT. XYZ merupakan perusahaan manufaktur yang bergerak dalam bidang produksi Stainless Steel Coil. PT. XYZ berharap dapat mengurangi pemborosan dalam proses produksinya, sehingga perusahaan dapat mendapatkan laba yang lebih besar dan mampu bersaing di industri saat ini. Tujuan dari penelitian yang dilakukan adalah untuk mengidentifikasi, mereduksi dan memberikan usulan perbaikan terhadap pemborosan (waste) pada proses produksi Stainless Steel Coil. Metode yang digunakan adalah konseplean manufacturing dengan tools value stream mapping dan bantuan metode Failure Mode and Effect Analysis (FMEA). Berdasarkan hasil penelitian pada value stream mapping didapatkan reduksi waktu dari 461 menit atau 27.660 detik menjadi 416 menit atau 24.960 detik. Berdasarkan Failure Mode and Effect Analysis (FMEA) diketahui akar penyebab masalah pada pemborosan (waste) tertinggi adalah Set up hot bucket yang kurang sesuai dan terjadi unplanned downtime atau kurang perawatan mesin. Rekomendasi perbaikan yang dapat diusulkan yaitu pembuatan jadwal pengurasan atau pembersihan hot bucket serta pengetatan terhadap set-up waktu hot bucket dan memperketat jadwal perawatan atau maintainance pada mesin Rolling Mill.

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APLIKASI LEAN SIX-SIGMA UNTUK MENGURANGI PEMBOROSAN DI BAGIAN PACKAGING SEMEN

JISI: Jurnal Integrasi Sistem Industri ◽

10.24853/jisi.7.2.143-153 ◽

2020 ◽

Vol 7 (2) ◽

pp. 143

Author(s):

Reni Dwi Astuti ◽

Lathifurahman Lathifurahman

Keyword(s):

Failure Mode ◽

Six Sigma ◽

Lean Manufacturing ◽

Fish Bone ◽

Lean Six Sigma ◽

Value Stream Mapping ◽

Effect Analysis ◽

Value Stream ◽

Transportation Motion

Hasil observasi di PT. Holcim Indonesia Tbk, pabrik Cilacap, didapati banyaknya pemborosan di bagian pengepakan semen, termasuk banyaknya produk cacat kemasan, sehingga banyak semen tercecer dan harus mengulangi proses pengepakan. Penelitian ini dilakukan untuk mengidentifikasi pemborosan selama proses pengepakan menggunakan pendekatan lean manufacturing dengan value stream mapping. Sementara tingkat kualitas dianalisis dengan metode six-sigma. Penyebab kecacatan produk dianalisis dengan fish-bone diagram. Failure Mode and Effect Analysis (FMEA) digunakan untuk merancang ususlan perbaikan. Pemborosan yang teridentifikasi meliputi : transportation, motion, waiting, over processing, dan defect. Usulan perbaikan untuk mengurangi pemborosan yaitu dengan penggabungan stasiun penimbangan dan stasiun pemeriksaan, sehingga memberikan estimasi peningkatan process cycle effisiensi dari 39,1% menjadi 46,69. Sedangkan upaya untuk mengurangi cacat produk dilakukan dengan perawatan preventif mesin packer.

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Waste Assessment in an Indian Casting Industry: A step towards Lean Manufacturing

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.c8686.019320 ◽

2020 ◽

Vol 9 (3) ◽

pp. 1861-1866

Keyword(s):

Lean Manufacturing ◽

Assessment Model ◽

Relationship Matrix ◽

Analysis Tool ◽

Effect Analysis ◽

Value Stream ◽

Slag Inclusions ◽

Casting Industry ◽

Set Up ◽

Assessment Questionnaire

In today’s era of globalization, it is essential to ensure that Indian manufacturing industries like casting and metal-working industries which work on stringent conditions of varying customer demands and constant adhering to excellent quality standards are able to flourish in the fiercely competitive environment while keeping the production as economical as possible. Hence, the need arises for continuous improvement in the manufacturing phase of the product by assessing, minimizing, and eliminating wastes of any kind. This study adopts and implements a waste assessment model in a casting industry with the purpose of assessment of wastes and hence, proceed towards a leaner manufacturing set-up. Initially, the quantification of direct relationships between the seven types of wastes was done by forming a waste relationship matrix (WRM). Next, a waste assessment questionnaire (WAQ) consisting of 68 questions, was introduced for the allocation of wastes in the industry. The results of WRM and WAQ were integrated to obtain the ranks of the seven types of wastes in the industry, and it was found that waste of defects was the highest-ranked waste followed by wastes of inventory and overproduction. Process Activity Mapping (PAM) received the highest score (482.79) in the analysis done by Value Stream Analysis Tool (VALSAT), thus, it was chosen as the preferred tool in the current situation. The results of Failure Mode and Effect Analysis (FMEA) of various defects of casting indicated sand inclusions (432) and slag inclusions (336) as the defects having the highest Risk Priority Numbers (RPN).

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

Jurnal Energi Dan Manufaktur ◽

10.24843/jem.2020.v13.i01.p07 ◽

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.

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IMPLEMENTASI LEAN MANUFACTURING PADA PROSES PRODUKSI UNTUK MENGURANGI WASTE GUNA LEBIH EFEKTIF DAN EFISIEN

Jurnal SENOPATI : Sustainability, Ergonomics, Optimization, and Application of Industrial Engineering ◽

10.31284/j.senopati.2020.v1i2.537 ◽

2020 ◽

Vol 1 (2) ◽

pp. 85-95

Author(s):

Edwin Bayu Kurniawan ◽

Ni Luh Putu Hariastuti

Keyword(s):

Failure Mode ◽

Lean Manufacturing ◽

Effect Analysis ◽

Value Stream ◽

Analysis Tools ◽

Industrial Coating ◽

Cycle Efficiency

CV. Nipson Industrial Coating adalah perusahaan yang hanya bergerak untuk memproduksi coating, dimana perlu terus menerus meningkatkan kinerja perusahaan untuk meningkatkan kualitas dan tepat waktu dalam pengiriman ke pada konsumen. Dengan strategi lean manufacturing perusahaan mampu mengidentifikasi jenis pemborosan (waste) yang terjadi dalam proses produksi sehingga waste yang terjadi bisa dihilangkan. Pemborosan (waste) diidentifikasi dengan seven waste, kemudian dilakukan pemetaan secara detail dengan Value Stream Analysis Tools (VALSAT) dan dianalisa akar penyebab masalah dengan Failure Mode and Effect Analysis (FMEA). Dari hasil penelitian ini, didapatkan pemborosan (waste) pada proses produksi adalah waiting/delay dan defect. Dampak dari penerapan strategi lean manufacturing pada proses produksi menurut process activity mapping, meningkatkan process cycle efficiency menjadi 94.84% dan menurut quality filter mapping adalah melaksanakan standarisasi pada material bahan baku kemudian melakukan pelatihan terhadap pekerja dikhususkan terhadap bidangnya masing-masing. Kata Kunci : Lean Manufacturing, Waste, VSM, VALSAT, FMEA

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Peningkatan Produktivitas Leaf Spring Jenis Minicup Tipe MMS 2230 dengan Mengurangi Pemborosan Proses Produksi Melalui Penerapan Metode Lean Manufacturing

Jurnal Rekayasa Sistem Industri ◽

10.26593/jrsi.v10i1.3813.89-100 ◽

2021 ◽

Vol 10 (1) ◽

pp. 89-100

Author(s):

Suparno Suparno ◽

Agus Selamet Susanto

Keyword(s):

Lean Manufacturing ◽

Value Stream Mapping ◽

Leaf Spring ◽

Effect Analysis ◽

Productivity Level ◽

Value Stream ◽

Mode Effect ◽

Mapping Analysis ◽

Fishbone Diagram ◽

Failure Mode Effect Analysis

PT. Indospring is a manufacturing company that produces various springs for an automotive. Among those various springs, MSM 2230 type is the most produced spring at the company. The big problem in producing the spring was related with the high waste that had impact on the low productivity. The purpose of study was to analyze the waste by using the concept of lean manufacturing particularly to identify and eliminate nonvalue added activities. The study found that there were various wastes which waiting and excessive transportation were two dominant wastes with the contribution to total of wastes at 28.96% and 18.52% respectively. The appropriate tool for further analysis on wastes was selected by using value stream mapping analysis (VALSAT), and process activity mapping (PAM) was the best tool for analyzing wastes more profoundly. The use of PAM and other tools of fishbone diagram and failure mode effect analysis (FMEA) provided important information for improvement. The implementation of improvement displayed potential increase of productivity level by reducing the processing time of the spring from 113,926.83 minutes to 75,960 minutes

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PERBAIKAN KUALITAS PROSES PRODUKSI DENGAN PENDEKATAN LEAN-SIGMA DI PT. AUTOKORINDO PRATAMA, GRESIK

Jurnal IPTEK ◽

10.31284/j.iptek.2016.v20i2.21 ◽

2016 ◽

Vol 20 (2) ◽

pp. 1

Author(s):

Ni Luh Putu Hariastuti ◽

Rony Nur Cahya

Keyword(s):

Failure Mode ◽

Six Sigma ◽

Value Stream Mapping ◽

Effect Analysis ◽

Pareto Chart ◽

Value Stream ◽

Fishbone Diagram

PT. Autokorindo Pratama Gresik adalah sebagai salah satu produsen velg truck dan bus di Indonesia. Penelitian ini menitiberatkan pada penggabungan konsep lean manufactur dan konsep six sigma yaitu lean sigma untuk memperbaiki kualitas. Tools lean sigma yang dipakai pada penelitian ini adalah Value Stream Mapping, pareto chart, fishbone diagram, dan Failure Mode and Effect Analysis. Dari hasil penelitian diperoleh waste terkritis yaitu waste defect, waste motion, dan transportation dan waste waiting pada proses produksi disc, rim, ring, assy, dan paint. Dalam penelitian ini jenis waste defect tertinggi adalah dimensi part tidak sesuai pada proses expanding yang terdapat pada proses produksi rim dengan jumlah defect 1900 unit. Dan waste transportation adalah jarak antara proses assy dengan proses paint sejauh 100 m. Dengan perbaikan ini diharapkan dapat menyelesaikan masalah yang berkaitan dengan meminimalisasi terjadinya waste defect, waiting, motion, dan transportation. Kata Kunci : Waste, Lean Sigma,Value Stream Mapping, Pareto Chart, Fishbone Diagram, dan Failure Mode and Effect Analysis.

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Perancangan Perbaikan Proses Produksi Komponen Bodi Mobil Daihatsu dengan Lean Manufacturing di PT. “XYZ”

Jurnal Studi Manajemen dan Bisnis ◽

10.21107/jsmb.v5i2.6667 ◽

2020 ◽

Vol 5 (2) ◽

pp. 122-129

Author(s):

Satria Khalif Isnain ◽

Putu Dana Karningsih

Keyword(s):

Production Process ◽

Lean Manufacturing ◽

Early Observation ◽

Borda Count ◽

Value Stream Mapping ◽

Positive Signal ◽

Effect Analysis ◽

Value Stream ◽

Potential Market ◽

Product Part

Astra Daihatsu Motor Company. Potential market for automotive is continuously growing which is positive signal for automotive businesses. However nowadays competition is also getting stronger. Therefore PT Inti Pantja Press Industri should efficiently manage their production. One way is by reducing and eliminating waste in its production. Production process in PT. Inti Pantja Press Industri is still having several problems. Based on early observation there are bottleneck in subassy processes and also defective product. Reffering to these problems, it can be indicated that there are several waste in production process of PT. Inti Pantja Press Industri.Therefore, Lean Manufacturing approach is utilized to reduce or eliminate waste in production processes. First, various waste are identified using Value Stream Mapping. Borda Count Method is used for determining critical waste that occur, they are as follow: waste waiting, defect, and overproduction that cause over inventory finish product. Then, 5 Whys Analysis specifies root causes of waste waiting and waste defect. By using Failure Mode and Effect Analysis, highest priority of root causescan be selected, which are operator do not clean dies before press process, operator do not replace components that has already over its lifetime (wear) and rust on finish product part. Recommendations for improvements are conducted by implementating Poka Yoke method, they are: installation of sensors and equipment in Press machines and wrapping finish part product.

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