Penerapan lean manufacturing untuk mencapai target produksi island bench wooden based pada PT. Karya Nadiso Utama

DETAIL KOLEKSI

Penerapan lean manufacturing untuk mencapai target produksi island bench wooden based pada PT. Karya Nadiso Utama

Oleh : Deaprilia Nabila Sari

Info Katalog

Penerbit : FTI - Usakti

Kota Terbit : Jakarta

Tahun Terbit : 2022

Pembimbing 1 : Didien Suhardini

Pembimbing 2 : Sumiharni Batubara

Subyek : Production control;Lean manufacturing

Kata Kunci : lean manufacturing, value stream mapping, waste assessment model

Status Posting : Published

Status : Lengkap

File Repositori

No.	Nama File	Hal.
1.	2022_TA_STI_063001800075_-Halaman-Judul.pdf
2.	2022_TA_STI_063001800075_-Lembar-Pengesahan.pdf	3
3.	2022_TA_STI_063001800075_-Bab-1_Pendahuluan.pdf
4.	2022_TA_STI_063001800075_-Bab-2_Tinjauan-Pustaka.pdf
5.	2022_TA_STI_063001800075_-Bab-3_Metodologi-Penelitian.pdf
6.	2022_TA_STI_063001800075_-Bab-4_Analisis-dan-Pembahasan.pdf
7.	2022_TA_STI_063001800075_-Bab-5_Kesimpulan.pdf	2
8.	2022_TA_STI_063001800075_-Daftar-Pustaka.pdf

Abstrak
Abstract

P T. Karya Nadiso Utama merupakan perusahaan manufaktur yang memproduksi peralatan laboratorium dan furniture menggunakan mesin otomatis dengan sistem produksi make-to-order. Island Bench Wooden Based merupakan produk yang memiliki jumlah permintaan yang tinggi dan selalu diproduksi di setiap bulan. Permasalahan yang terjadi adalah tidak tercapainya rata-rata target produksi Island Bench Wooden Based pada bulan Mei, Juni, Juli, September dan Oktober 2021 sebesar 12 unit/bulan yang disebabkan karena adanya kegiatan yang bersifat pemborosan pada proses produksi yang akan mempengaruhi jumlah produk yang dihasilkan dan akan berdampak terhadap kepuasan customer. Pada penelitian ini digunakan pendekatan lean manufacturing. Tujuan penelitian ini yaitu mendapatkan hasil rancangan perbaikan proses produksi Island Bench Wooden Based untuk mengurangi manufacturing lead time dengan menggunakan pendekatan lean manufacturing, sehingga target produksi PT. Karya Nadiso Utama dapat tercapai. Penelitian diawali melakukan perhitungan waktu baku, peta aliran proses, lalu dilakukan perhitungan waste assessment model yang menghasilkan waste dominan yang terjadi pada proses produksi Island Bench Wooden Based yaitu waste defect sebesar 30.769%, waste transportation sebesar 23.077%, dan waste motion sebesar 15.385%. Selanjutnya dilakukan pemetaan current value stream mapping yang menghasilkan manufacturing lead time sebesar 1668.049 menit, process cycle efficiency sebesar 69.258% dan total produksi sebesar 11 unit/bulan. Usulan perbaikan yang diberikan yaitu memberikan stiker berwarna pada bahan baku HPL, mengeleminasi aktivitas operator mempersiapkan bahan baku plywood, meletakkan tempat penyimpanan tools pada SK pelapisan, mengeleminasi aktivitas operator mempersiapkan lem kayu, mengeleminasi aktivitas melakukan inspeksi terhadap bahan baku HPL dan plywood, mengeleminasi aktivitas melakukan pengecekan terhadap mesin press, mengeleminasi aktivitas melakukan pengecekan terhadap mesin cutting, mengeleminasi aktivitas melakukan pengecekan terhadap mesin edging, mengeleminasi aktivitas melakukan pengecekan terhadap mesin skipper, mengeleminasi aktivitas melakukan pengecekan terhadap mesin panel saw, menggunakan pallet trolley untuk aktivitas pallet dipindahkan ke trolley, menggunakan storage cart pada stasiun kerja perakitan dan packaging, dan melakukan kegiatan preventive maintenance untuk komponen cacat akibat panel dan mata bor pada mesin terkadang error. Setelah melakukan perbaikan, penyederhanaan aktivitas dilakukan sehingga aktivitas proses produksi yang semula ada 113 aktivitas menjadi 97 aktivitas. Lalu dilakukan pembuatan peta aliran proses usulan dan pembuatan future value stream mapping yang menghasilkan manufacturing lead time sebesar 1492.161 menit, process cycle efficiency usulan sebesar 77.422%, dan total produksi sebesar 13 unit/bulan. Sehingga target produksi perusahaan sudah tercapai.

P T. Karya Nadiso Utama is a manufacturing company that produces laboratory equipment and furniture using automatic machines with a make-to-order production system. Island Bench Wooden Based is a product that has a high number of requests and always produced every month. The problem that occurs is that the average Island Bench Wooden Based production target is not achieved in May, June, July, September and October 2021 of 12 units/month due to wasteful activities in the production process which will affect the number of products produced and will have an impact on customer satisfaction. In this study, a lean manufacturing approach was used. The purpose of this study was to obtain the results of an Island Bench Wooden Based production process improvement design to reduce manufacturing lead time by using a lean manufacturing approach, so that the production target of PT. Karya Nadiso Utama's work can be achieved. The study begins by calculating the standard time, process flow map, then calculating the waste assessment model that produces the dominant waste that occurs in the Island Bench Wooden Based production process, namely defect waste of 30,769%, transportation waste of 23.077%, and motion waste of 15.385%. Furthermore, a current value stream mapping was carried out which resulted in a manufacturing lead time of 1668,049 minutes, a process cycle efficiency of 69.258% and a total production of 11 units/month. The proposed improvements are providing colored stickers on HPL raw materials, eliminating the activities of operators preparing plywood raw materials, placing tools storage on coating work stations, eliminating the activities of operators preparing wood glue, eliminating activities inspecting HPL and plywood raw materials, eliminating activities checking the press machine, eliminating the activity of checking the cutting machine, eliminating the activity of checking the edging machine, eliminating the activity of checking the skipper machine, eliminating the activity of checking the panel saw machine, using the pallet trolley for pallet activities to be transferred to the trolley, using storage carts at assembly and packaging work stations, and perform preventive maintenance activities for defective components due to panels and drill bits on machines that sometimes error. After making improvements, simplification of activities was carried out so that the production process activities which originally had 113 activities became 97 activities. Then, the proposed process flow map and future value stream mapping were made which resulted in a manufacturing lead time of 1492,161 minutes, a process cycle efficiency of 77.422%, and a total production of 13 units/month. So that the company's production target has been achieved.