5S Implementation to Minimize Waste in Bread Production Process (Case Study: Madani Bakery)

Abstract

This paper aimed to implement the 5S concept at Madani Bakery by using PDCA (Plan, Do, Check, and Action) to reduce waste. The problems found in the bread industry have not implemented 5S so that there is waste during production activities. The method that can be used to overcome these problems is to apply 5S and PDCA so that they can make continuous improvements. The initial data used is the result of observing the initial conditions before implementing 5S and then determining Plan, Do, Check, and Action (PDCA). Based on observations at Madani bakery, two types of waste were found, namely unnecessary motion and transportation. Madani Bakery has not yet fully implemented 5S, there is still dust, items are in random condition, and there are still unused items at the work station. 5S deployments are designed to improve workstations and reduce unnecessary waste movement and transportation. The limitation of this research is that the application of 5S is carried out according to the conditions of the production area at Madani Bakery. This research can be useful for Madani Bakery to create a comfortable work environment and reduce working time caused by waste during production activities. This research is expected to help Madani Bakery to implement 5S so that it becomes a work culture to reduce waste. Repairs to work stations at Madani Bakery can be used in other industries in implementing 5S and creating a work culture. Working time was cut to 784.34 min, and waste was cut to 11.773 min.