SETIAWAN, IWAN (2023) IMPLEMENTASI VALUE STREAM MAPPING GUNA MENINGKATKAN PERFORMA PROSES PRODUKSI GRAVURE INK DI SEBUAH CHEMICAL COMPANY. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
This research was conducted on a chemical company whose main product is printing ink for various printing techniques such as gravure, offset, flexo, etc. In the production process of rotogravure inks 2, excessive production frequently occurs due to the excessive adjustment process in the adjustment/color matching process. The purpose of this study is to determine the main factors of waste that occur in the process, furthermore understand the VA, NVA, and NNVA, in order to eliminate the root cause of waste. Lean manufacturing tools, VSM, VALSAT and FMEA were used in this study. The results show that 17.9 % of the waste was overproduction, 17.3 % was overprocessing and 15.6 % was waiting time. According to the FMEA analysis, the root cause of overproduction was the inappropriate material used for development in the technical lab, the root cause of over processing was the discrepancy in the measurement results of the instruments, and the root cause of waiting was the employees searching for materials due to poor storage facilities and ERP data validation. Suggestions for improvement include conducting periodic material replacement, conducting periodic instrument validation, and ensuring proper SAP updates. The total lead time that can be reduced is 106.4 minutes (48%). Keyword: Lean manufacturing, VSM, VALSAT, FMEA Perusahaan tempat penelitian ini dilakukan merupakan sebuah chemical company yang produk utamanya adalah, printing ink untuk berbagai kebutuhan teknik cetak, seperti gravure, offset, flexo, dll. Pada proses produksi gravure ink plant 2 diketahui bahwa sering timbul produksi berlebihan yang terjadi sebagai akibat dari proses adjustment yang berlebihan pada proses adjustment/color matching. Tujuan dari penelitian ini adalah untuk mengetahui main factor waste yang terjadi pada proses, memahami apa saja kegiatan yang termasuk kedalan VA, NVA, dan NNVA agar dapat merumuskan usaha untuk mengeliminasi secara tepat root cause dari waste. Penelitian ini dilakukan menggunakan metode lean manufacturing dengan tools, VSM, VALSAT, dan FMEA. Dari hasil analisa diketahui waste teridentifikasi adalah over production (17,9%), over processing (17,3%), dan waiting (15,6%). Setelah melakukan analisa penyebab masalah menggunakan FMEA diketahui bahwa, material yang digunakan untuk developement di technical lab sudah tidak layak pakai merupakan root cause dari over production, Deviasi hasil pengukuran instrument merupakan root cause dari over processing, dan Operator mencari material akibat kurang baiknya sistem storage, dan validasi data ERP merupakan root cause dari waiting. Saran perbaikan antara lain melakukan penggantian material berkala, melakukan validasi instrumen berkala, dan memastikan update SAP dengan baik. Total lead time yang dapat dikurangi adalah 106,4 menit (48%). Kata kunci: Lean Manufacturing, Value Steam Mapping, VALSAT, FMEA
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