PUTRA, FIBI EKO (2020) ANALISIS WASTE DAN PENGEMBANGAN LEAN MANUFACTURING PADA INDUSTRI KOMPONEN ALAT BERAT. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
Competition in the heavy equipment industry in Indonesia is getting tighter. Increased demand for heavy equipment needs the coal industry in Indonesia and coupled with the support of the Indonesian Ministry of Industry in the downstream of coal, the heavy equipment industry can also increase production. The application of lean manufacturing with a value strea, mapping approach is carried out to analyze the waste that occurs in each expenditure process. Based on the results of the analysis in this study, the identification of residuals in the machining process of head rod products explains that the low level of achievement of expenditures results in differences between the achievement of expenditure and expenditure targets. The current state mapping shows that there is a high processing period for beld weld and drill+tap. Meanwhile, the number of rejections generated was with a sigma value of 2.79 in that period. The types of waste obtained include processing, movement, transportation, inventory and defects. Identification of the cause is carried out using the 5W1H approach and why-why analysis in the Focus Group Discussion (FGD) of related parties including human factors, machines, materials, and methods. From the results of the future state mapping, there is a decrease in production time of the machine setting in the beld weld process by 23.68% and the drill+tap process by 24.74%. Meanwhile, the ratio between mapping the current state mapping and the future state mapping to the sigma value has increased by 6.02%. Keywords: Lean Manufacturing, value stream mapping, why-why analysis, 5W1H. Persaingan di industri alat berat di Indonesia semakin ketat. Meningkatnya permintaan akan kebutuhan alat berat pada industri batubara di Indonesia dan ditambah dengan dukungan Kementerian Perindustrian RI dalam hilirisasi batubara, maka industri alat berat juga dapat meningkatkan produksi. Penerapan lean manufacturing dengan pendekatan value stream mapping dilakukan untuk menganalisa waste yang terjadi pada setiap proses produksi. Berdasarkan hasil analisis dalam penelitian ini bahwa identifikasi waste dalam proses machining produk head rod menjelaskan tingkat pencapaian produksi yang rendah mengakibatkan terjadi perbedaan antara pencapaian produksi dengan target produksi. Pada current state mapping menunjukkan bahwa terdapat waktu proses yang tinggi untuk proses beld weld dan drill+tap. Sementara itu, untuk jumlah reject yang dihasilkan yaitu dengan nilai sigma sebesar 2,79 pada periode tersebut. Jenis waste yang didapatkan antara lain adalah processing, motion, transportation, inventory, dan defect. Adapun identifikasi penyebab dilakukan dengan pendekatan 5W1H dan why-why analysis pada Focus Group Discussion (FGD) terhadap pihak yang terkait meliputi faktor manusia, mesin, material, dan metode. Dari hasil future state mapping bahwa terjadi penurunan waktu produksi pada setting mesin dalam proses beld weld sebesar 23,68% dan proses drill+tap sebesar 24,74%. Sedangkan perbandingan antara current state mapping dengan future state mapping terhadap nilai sigma mengalami peningkatan sebesar 6,02%. Kata kunci: Lean Manufacturing, value stream mapping, why-why analysis, 5W1H.
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