MOLLE, TOSAN DANUMAYA (2021) PENGEMBANGAN SISTEM MANUFACTURING MELALUI ANALISA WASTE DENGAN KONSEP LEAN DI INDUSTRI PLASTIK. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The development of the industry in world free trade is growing rapidly. Demand for the needs of automotive components in the Asian market, especially in Indonesia, is increasing, as well as additional support from the Government through the ministry of industry terms of economic development, the automotive components industry has increased production when referring to this demand in maintaining and increasing the market for automotive component products. This increase affects the need for plastics as a raw material for automotive components, which also increases production. Based on the results of the analysis in this study, waste identification in the injection molding process of S / A gear worm product explains that a low level of production achievement results in a significant difference between production achievement and target and production targets on S / A gear worm for automotive components. The current state mapping shows that there is a high processing time for the injection molding process and shaft assembly with direct measurement of processing time. Meanwhile, the total rejection generated was with a sigma value of 3.38 during the period. The types of waste obtained include processing, movement, transportation, inventory, and defects. Identification of causes is done using the 5W1H approach and analysis of why in Focus Group Discussion (FGD) parties related to these causes which include human factors, machines, materials, and methods. From the results of mapping the situation in the future, there is a decrease in the activity time of the machine setting process in the injection molding process by 32.70%, and a decrease in the time for the shaft assembly process by 37.82%. Meanwhile, the comparison between the current state mapping and the future state mapping of the sigma value has increased by 7.36%. Keywords: Lean Manufacturing, why-why analysis, 5W1H. Perkembangan industri di perdagangan bebas dunia semakin maju pesat. Permintaan atas kebutuhan komponen otomotif di pasar Asia terutama di Indonesia semakin meningkat, serta ditambahnya dukungan dari Pemerintah lewat kementrian perindustrian dalam hal pembangunan ekonomi, maka Industri komponen otomotif mengalami peningkatan produksi apabila mengacu pada permintaan tersebut dalam menjaga dan meningkatkan pasar pada produk komponen otomotif. Peningkatan ini berdampak pada kebutuhan plastik sebagai bahan baku untuk komponen otomoitf yang juga mengalami peningkatan produksi. Berdasarkan hasil analisis dalam penelitian ini bahwa identifikasi waste dalam proses injection molding produk gear worm S/A menjelaskan tingkat pencapaian produksi yang rendah mengakibatkan perbedaan yang cukup signifikan antara pencapaian produksi dan target dengan target produksi pada gear worm S/A untuk komponen otomotif. Pada current state mapping menunjukkan bahwa terdapat waktu proses yang tinggi untuk proses injection molding dan shaft assembly dengan pengukuran langsung terhadap waktu proses. Sementara itu, untuk jumlah reject yang dihasilkan yaitu dengan nilai sigma sebesar 3,38 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 dengan penyebab tersebut yang meliputi faktor manusia, mesin, material, dan metode. Dari hasil future state mapping bahwa terjadi penurunan waktu aktivitas proses setting mesin pada proses injection molding sebesar 32,70%, dan penurunan waktu pada proses shaft assembly sebesar 37,82%. Sedangkan perbandingan antara current state mapping dengan future state mapping terhadap nilai sigma mengalami peningkatan sebesar 7,36%. Kata kunci: Lean Manufacturing, why-why analysis, 5W1H.
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