PENERAPAN LEAN MANUFACTURING DALAM MENINGKATKAN PRODUKTIVITAS DENGAN METODE VSM DAN PAM (Studi kasus pada industri Fasteners)

KOMALUDIN, DEDE ABDULAH (2020) PENERAPAN LEAN MANUFACTURING DALAM MENINGKATKAN PRODUKTIVITAS DENGAN METODE VSM DAN PAM (Studi kasus pada industri Fasteners). S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

PT Garuda Metalindo Tbk. is a private company which produces automotive component products, namely fasteners (fasteners). Delay delivery is a problem that often occurs that is detrimental to consumers and internal companies. Product, Pin Brake Shoe Anchor M8 x 55.2 mm is the product with the most frequent delay in delivery. From company data during February 2020 there were 15 times with an outstanding number of 252,525. This research was conducted by applying value stream mapping and process activity mapping methods. From the results of the depiction using the value stream mapping method, the bottleneck of the process occurs in the machining-2 process where the production output cannot meet the daily demands of consumers, namely 16,818 pcs/day. From the observations on the machining-2 process, the cycletime machining-2 process is longer than the other processes, namely 2pcs/minute (30 seconds/pcs) which can only produce 2,490 pcs/machine/day output. Using the process activity mapping method, at Machining-2 process is known to have the value added value of the process which is 4 seconds (13%) while the Necessary Non Value Added is 26 seconds (87%), this happen because there is an activity that is not needed in the process of loading-unloading the product on the CNCFCL120A machine. The results of improvements with automation show an increase in the cycletime of the machining-2 process to 17pcs/minute (3.53 seconds/pcs) which results in an output of 21,165 Pcs/machine/day, a decrease in the number of WIP stock from 66,180pcs to 1,440pcs, and a decrease in the leadtime of the machining-2 production process. from 3722 minutes (223,320 seconds) to 81,208 minutes (4872 seconds). Keywords: lean manufacturing, VSM, PAM, Bottleneck, Automation, Machining PT Garuda Metalindo Tbk. merupakan sebuah perusahaan swasta yang memproduksi produk komponen otomotif yaitu fasteners (pengikat). Delay delivery merupakan permasalahan yang sering terjadi yang merugikan konsumen dan internal perusahaan. Produk Pin, Brake Shoe Anchor M8 x 55.2 mm merupakan produk yang paling sering terjadi delay delivery. Dari data perusahaan selama bulan Februari 2020 terjadi sebanyak 15 kali dengan jumlah outstanding 252.525 Pcs. Penelitian ini dilakukan dengan menerapkan metode value stream mapping dan process activity mapping. Dari hasil penggambaran dengan metode value stream mapping, bottleneck proses terjadi pada proses machining-2 yang dimana output produksi tidak dapat memenuhi permintaan harian konsumen yaitu 16.818pcs/hari. Dari hasil pengamatan pada proses machining-2, cycletime proses machining-2 lebih lama dibandingkan dengan proses lainnya yaitu 2pcs/menit (30 detik/pcs) yang hanya dapat menghasilkan output 2.490 Pcs/mesin/hari.Dengan menggunakan metode process activity mapping, pada proses machining-2 diketahui nilai value added dari proses tersebut yaitu 4 detik (13%) sedangkan Necessary Non Value Added yaitu 26 detik (87%), hal tersebut terjadi karena adanya aktivitas yang tidak diperlukan pada poses loading – unloading produk di mesin CNCFCL120A. Hasil perbaikan dengan otomatisasi diketahui adanya peningkatan cycletime proses machining-2 menjadi 17pcs/menit (3.53 detik/pcs) yang menghasilkan output 21.165 Pcs/mesin/hari, terjadi penurunan jumlah stock WIP dari 66.180pcs menjadi 1.440pcs, serta menurunkan leadtime proses produksi machining-2 dari 3722 menit (223.320 detik) menjadi 81.208 menit (4872 detik). Kata kunci: lean manufacturing, VSM, PAM, Bottleneck, Otomatisasi, Machining.

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