DAMSIAR, DAMSIAR (2020) ANALISA WASTE UNTUK PENINGKATAN PRODUKTIVITAS LINE METAL PRESS PADA INDUSTRI DISCBRAKE SEPEDA MOTOR MENGGUNAKAN METODE LEAN MANUFACTURING. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The motorcycle component industry as part of the national strategic industry has made a significant contribution to the country's economic growth. Problems still faced are the availability of most of the materials still imported, mastery of the latest technology, and low production targets. Based on the results of previous research and discussions with supervisors, the main causes are the use of low machine time and low work productivity. Based on further analysis, both of these things happen due to inaccurate selection of production systems and poor machine layout, which leads to a lot of wastage which results in high processing time and production lead time. This paper aims to help eliminate and reduce the waste that appears in metal press lines by applying lean manufacturing principles and strategies such as work study, production system (one flow system), machine layout, kaizen, and line balancing. As a result of the improvements made, the waste of activities without added value can be reduced by 15 activities which affects the increase in machine efficiency by 21.5%, machine utility by 18.2%, and work productivity by 27%. As a result, the achievement of production targets increased from 85.2% to 94.7% and other benefits both directly and indirectly. Keywords : Productivity, lean manufacturing, work study, layout, line balancing Industri komponen sepeda motor sebagai bagian dari industri strategis nasional telah memberikan kontribusi riil terhadap pertumbuhan ekonomi nasional. Permasalahan yang masih dihadapi adalah ketersediaan sebagian besar materialnya masih impor, penguasaan teknologi terkini, dan masih rendahnya pemenuhan target produksi. Berdasarkan hasil penelitian terdahulu dan diskusi dengan penyelia, penyebab utamanya adalah masih rendahnya penggunaan waktu efektif mesin dan rendahnya produktivtias kerja. Berdasarkan analisa lanjutan kedua hal tersebut terjadi karena kurang tepatnya pemilihan sistem produksi dan layout mesin yang kurang baik sehingga menimbulkan banyak waste yang menyebabkan tingginya waktu proses dan lead time produksi. Tulisan ini bertujuan untuk membantu menghilangkan dan mengurangi waste yang muncul pada line metal press dengan menggunakan implementasi prinsip, strategi, dan tools lean manufacturing seperti work study, sistem produksi (one flow system), layout mesin, kaizen, dan line balancing. Dari hasil perbaikan yang dilakukan, waste aktivitas non value added dapat dikurangi sebanyak 15 aktivitas yang berdampak pada naiknya efisiensi mesin sebesar 21,5%, utilitas mesin sebesar 18,2%, dan produktivtias kerja sebesar 27%. Sebagai hasil akhirnya pencapaian target produksi naik dari 85,2% menjadi 94,7% dan manfaat lainnya baik langsung maupun tidak langsung. Kata Kunci : Produktivitas, lean manufacturing, work study , layout, line balancing
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