PERBAIKAN LEAD-TIME PENGERJAAN KAM CUTTER DENGAN METODE POKA-YOKE

JUNIAWAN, SINGGIH (2025) PERBAIKAN LEAD-TIME PENGERJAAN KAM CUTTER DENGAN METODE POKA-YOKE. S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

The KAM Cutter is a cutting blade used to manufacture plastic pellets through underwater pelletizing. A manufacturing company in Cikarang reported that, on average, an order completion rate for KAM Cutter for 2023-2024 was 12,51%, which is highly below expectations. This research will improve production capacity by enhancing lead time on the production floor. Lean Manufacturing tools used in the research involve Value Stream Mapping, Fishbone Diagram, Poka- Yoke, and Fixture Design. The findings of this research have revealed that by using a new fixture design, the CNC Milling process can reduce the lead time from 15,24 minutes to 2,09 minutes per unit and reduce the Surface Grinding process from 14,88 minutes to 0,87 minutes per unit while maintaining an overall lead time reduction of 84,38%, from 32 minutes to 5 minutes per unit. The above improvements increased production capacity from 6.507 units/year to 49.518 units/year, approaching the target of 54.000 units/year while boosting the company's revenue from IDR 2,47 billion to IDR 18,81 billion per year. Besides, the Non-Value-Added process time was reduced by 68,72%, reflecting significant efficiency improvements in the production process. Keywords : Lead-Time, Kam Cutter, Value Stream Mapping, Poka-Yoke, Manufacture KAM Cutter merupakan pisau pemotong yang digunakan untuk memproduksi pelet plastik melalui proses underwater pelletizing. Sebuah perusahaan manufaktur di Cikarang melaporkan bahwa rata-rata tingkat penyelesaian pesanan KAM Cutter untuk tahun 2023–2024 hanya sebesar 12,51%, jauh di bawah ekspektasi. Penelitian ini bertujuan untuk meningkatkan kapasitas produksi dengan memperbaiki lead time di lantai produksi. Alat Lean Manufacturing yang digunakan dalam penelitian ini meliputi Value Stream Mapping, Fishbone Diagram, Poka-Yoke, dan Fixture Design. Hasil penelitian menunjukkan bahwa dengan menggunakan desain fixture yang baru, proses CNC Milling dapat memangkas lead time dari 15,24 menit menjadi 2,09 menit per unit, dan proses Surface Grinding berkurang dari 14,88 menit menjadi 0,87 menit per unit, dengan total pengurangan lead time sebesar 84,38%, dari 32 menit menjadi 5 menit per unit. Peningkatan ini mendorong kapasitas produksi dari 6.507 unit/tahun menjadi 49.518 unit/tahun, mendekati target 54.000 unit/tahun, serta meningkatkan pendapatan perusahaan dari Rp2,47 miliar menjadi Rp18,81 miliar per tahun. Selain itu, waktu proses yang tidak bernilai tambah (Non-Value-Added) berhasil dikurangi sebesar 68,72%, mencerminkan peningkatan efisiensi yang signifikan dalam proses produksi. Kata kunci : Lead Time, KAM Cutter, Value Stream Mapping, Poka-Yoke, Manufaktur

Item Type:	Thesis (S1)
Call Number CD:	FT/PPI. 25 017
Call Number:	ST/PPI/25/017
NIM/NIDN Creators:	52524110005
Uncontrolled Keywords:	Lead Time, KAM Cutter, Value Stream Mapping, Poka-Yoke, Manufaktur
Subjects:	600 Technology/Teknologi > 670 Manufacturing/Manufaktur, Pabrik-pabrik 600 Technology/Teknologi > 670 Manufacturing/Manufaktur, Pabrik-pabrik > 673 Nonferrous Metals Process/Pabrik Logam Bukan Besi > 673.4 Lead/Timah 700 Arts/Seni, Seni Rupa, Kesenian > 700. Arts/Seni, Seni Rupa, Kesenian > 702 Miscellany of Fine and Decorative Art/Aneka Ragam tentang Kesenian, Aneka Ragam tentang Karya Seni > 702.8 Techniques, Precedures, Apparatus, Equipment, Materials/Teknik, Prosedur, Perlengkapan, Peralatan, Bahan > 702.88 Maintenance and Repair/Perawatan dan Perbaikan
Divisions:	Fakultas Teknik > Program Profesi Insinyur
Depositing User:	khalimah
Date Deposited:	30 Jul 2025 04:30
Last Modified:	30 Jul 2025 04:30
URI:	http://repository.mercubuana.ac.id/id/eprint/96390

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