Daruki, Daruki (2026) IMPLEMENTASI LEAN MANUFACTURING DAN QUICK RESPONSE MANUFACTURING UNTUK MENGURANGI LEAD TIME PADA INDUSTRI FURNITUR. S2 thesis, Universitas Mercu Buana Jakarta - Menteng.
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Abstract
Industri furnitur sofa memiliki karakteristik produksi high-mix low-volume yang menyebabkan sistem produksi menjadi kompleks dan rentan terhadap penumpukan Work In Process (WIP). Kondisi ini berdampak pada panjangnya lead time yang tidak sebanding dengan waktu proses aktual. Analisis kondisi awal menunjukkan bahwa total Manufacturing Critical-path Time (MCT) mencapai 16,71 hari, dengan proporsi touch time hanya 1,09%, yang menandakan dominasi waktu tunggu dan inventory dalam sistem. Penelitian ini bertujuan menurunkan lead time melalui perbaikan aliran produksi berbasis Lean Manufacturing dan Quick Response Manufacturing (QRM). Penelitian bersifat terapan dengan menggunakan data primer dan sekunder yang diperoleh melalui observasi langsung, pengukuran waktu proses, serta dokumentasi produksi. Analisis dilakukan menggunakan Process Activity Mapping (PAM) dan Value Stream Mapping (VSM) untuk memetakan kondisi eksisting (current state) dan usulan (future state). Pendekatan QRM diterapkan melalui analisis MCT dan perancangan sistem POLCA sebagai mekanisme pengendalian aliran dan pembatasan WIP. Hasil perancangan future state menunjukkan bahwa integrasi Lean dan QRM menurunkan total MCT dari 16,71 hari menjadi 10,58 hari serta meningkatkan proporsi touch time dari 1,09% menjadi 1,6%. Penurunan ini menunjukkan bahwa pengendalian aliran dan pembatasan WIP lebih efektif dalam mengurangi lead time dibandingkan sekadar peningkatan efisiensi proses lokal. he sofa furniture industry is characterized by a high-mix, low-volume production environment, resulting in a complex production system that is highly susceptible to the accumulation of Work In Process (WIP). This condition leads to extended production lead times that are disproportionate to the actual processing time. The initial analysis indicates that the total Manufacturing Critical-path Time (MCT) reached 16.71 days, while the touch time accounted for only 1.09%, reflecting the dominance of waiting time and inventory within the production system. This study aims to reduce production lead time through improvements in production flow based on Lean Manufacturing and Quick Response Manufacturing (QRM). The research adopts an applied research approach utilizing primary and secondary data obtained through direct observation, process time measurement, and production documentation. The analysis was conducted using Process Activity Mapping (PAM) and Value Stream Mapping (VSM) to identify the existing condition (current state) and the proposed improvement (future state). Furthermore, the QRM approach was implemented through MCT analysis and the design of a POLCA system as a flow control mechanism and WIP limitation strategy. The results of the future state design demonstrate that the integration of Lean and QRM successfully reduced the total MCT from 16.71 days to 10.58 days and increased the proportion of touch time from 1.09% to 1.6%. This reduction indicates that flow control and WIP limitation are more effective in reducing lead time than merely improving local process efficiency.
| Item Type: | Thesis (S2) |
|---|---|
| NIM/NIDN Creators: | 55322110001 |
| Uncontrolled Keywords: | Lead Time, Lean Manufacturing, Value Stream Mapping, Quick Response Manufacturing, Manufacturing Critical-path Time, POLCA. Lead Time, Lean Manufacturing, Value Stream Mapping, Quick Response Manufacturing, Manufacturing Critical-path Time, POLCA. |
| Subjects: | 600 Technology/Teknologi > 670 Manufacturing/Manufaktur, Pabrik-pabrik |
| Divisions: | Pascasarjana > Magister Teknik Industri |
| Depositing User: | ARDIFTA DWI AFRIANI |
| Date Deposited: | 06 Mar 2026 01:38 |
| Last Modified: | 06 Mar 2026 01:38 |
| URI: | http://repository.mercubuana.ac.id/id/eprint/101412 |
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