ARINTIANA, A'ISYAH IKA (2023) IMPLEMENTASI LEAN MANUFACTURING UNTUK MEREDUKSI WASTE PROSES INSPEKSI QC PRODUK PANCREATIN DI PT METISKA FARMA DENGAN VALUE STREAM MAPPING DAN KAIZEN. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
This study aims to identify the causes of QC inspection’s leadtime which is too long, determine the corrective actions, and the risk mitigation of the corrective actions. Leadtime is target completion of a process. Inspection’s Leadtime is target completion of a one-time QC inspection process of pancreatin products. QC Inspection’s leadtime is too long, it causing the total production leadtime also be long and providing the potential for OSPO of pancreatin products. This may be due to potential waste in the QC inspection process of pancreatin products. The application of Lean Manufacturing is carried out to make improvements for this situation. VSM is used to describe the flow of the QC inspection process before and after improvement, and also to identify potential waste that occurs. Corrective actions were formulated using the Kaizen approach with fishbone diagram to analyze the root causes of waste, using 5W+2H table to formulate corrective actions, and also FMEA to analyze the risk mitigation of corrective actions. The results showed there are 2 kinds of waste in the QC inspection process of pancreatin products, overprocessing and waiting. The improvements succeed cutting the total QC inspection leadtime by 75% and 44.12% for total production leadtime. Keywords : Leadtime, Lean Manufacturing, VSM, Kaizen Penelitian ini bertujuan untuk mengidentifikasi penyebab leadtime inspeksi QC yang terlalu lama, menentukan usulan tindakan perbaikan, serta menentukan mitigasi resiko dari tindakan perbaikan yang diusulkan. Leadtime merupakan target penyelesaian suatu proses. Leadtime inspeksi QC merupakan target penyelesaian satu kali proses inspeksi QC dari produk pancreatin. Leadtime inspeksi QC dinilai terlalu panjang sehingga menyebabkan leadtime total produksi menjadi panjang dan memberikan potensi terjadinya OSPO terhadap produk pancreatin. Hal ini disebabkan adanya potensi waste dalam proses inspeksi QC produk pancreatin. Oleh sebab itu dilakukan penerapan Lean Manufacturing untuk melakukan perbaikan pada proses inspeksi QC tersebut. Proses inspeksi QC sebelum dan sesudah perbaikan digambarkan dengan VSM, kemudian dilakukan identifikasi potensi waste yang terjadi. Tindakan perbaikan dirumuskan menggunakan pendekatan Kaizen dengan alat fishbone diagram untuk analisa akar penyebab waste, tabel 5W+2H untuk merumuskan tindakan perbaikan, dan juga FMEA untuk analisa mitigasi resiko tindakan perbaikan. Hasil penelitian menunjukkan bahwa terdapat 2 macam waste dalam proses inspeksi QC produk pancreatin, yaitu overprocessing dan waiting. Dari perbaikan yang dilakukan berhasil memangkas leadtime total inspeksi QC sebesar 75% dan memangkas leadtime total proses produksi sebesar 44,12%. Kata Kunci : Leadtime, Lean Manufacturing, VSM, Kaizen
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