Penerapan Lean Manufacturing dengan Metode Takt Time dan FMEA untuk Mengidentifikasi Waste pada Proses Produksi Steril PT.XYZ

Hasanah, Tatun Uswatun; Wulansari, Tita; Putra, Tryana; Fauzi, Muchammad

doi:10.25124/jrsi.v7i2.435

Cited by 9 publications

(9 citation statements)

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“…Takt time is not a tool, it is a concept used to design a job and measure the tempo of customer demands. Takt Time (TT) is the time available to produce an item or service divided by the amount of products or services demanded by the customer in that period [23]. Each cycle time is fulfilling 5 demands out of 10 total demands.…”

Section: Tps Simulation Steps and Conditionsmentioning

confidence: 99%

Profit comparison analysis in production system simulation based on lean principles to achieve sustainable manufacturing

Mangngenre,

Indah,

Syamsul

et al. 2023

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Companies can achieve effective and efficient process if they make continuous improvements to achieve sustainability. In general, companies are aware of waste in the production process, but do not carry out measurements and analyzes related to this waste, including unit cost and profit analysis. A production system is needed that is able to minimize the unit costs and maximize profits in the company, one of the concepts used is the lean concept. This study aims to analyze the cost unit and profit generated in production systems that apply lean principles. Production system simulation is carried out using the concepts of Heijunka, Jidouka, and Kanban System. These three concepts are applied to a production system simulation that uses miniature cars with unit cost and profit comparison outputs with traditional production systems, pull systems, heijunka, jidouka, and Kanban systems. The results show that the unit cost of simulations 1 to 6 is getting lower, while the profit is increasing. In simulations 1 and 2 no profit was obtained because of implementing the traditional system while in simulations 3 to 6 there was an increase in profit because they had applied lean principles to the production system. Simulations that have implemented the lean concept have low unit costs and increasing profits, but what distinguishes the work methods applied. Production systems that apply the lean concept can help a company achieve sustainability in the economic field.

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Section: Tps Simulation Steps and Conditionsmentioning

confidence: 99%

Profit comparison analysis in production system simulation based on lean principles to achieve sustainable manufacturing

Mangngenre,

Indah,

Syamsul

et al. 2023

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Section: Formulation Of Improvement Recommendations and Future State ...mentioning

confidence: 99%

“…Formula (4) is used to obtain the takt time at 468 seconds. This indicates the company's capacity in generating 1 sack of product within the rate(Hasanah et al, 2020). The value is then compared with the standard time at each terminal.Two workstations, termed esterification and flaking, reported an extensive standard time, compared to the takt value.…”

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confidence: 99%

The Analysis of Lean Manufacturing in Waste Reduction During Rosin Ester Production at PT XYZ

2022

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Waste are commonly generated during the utilization of raw materials. Therefore, they are become important to consider lean manufacturing to achieve the overall business objectives. PT XYZ is a major company in processing pine resin and its derivatives, including gum rosin, turpentine and rosin ester, mainly used as featured commodities. During production, a certain amount of unwanted materials in the form of defect and in the form of work-in-process (WIP) that caused waiting wastes are obtained, particularly at the rosin ester floor. This study aims to identify the waste types and their dominant factors that caused waste occurred in PT XYZ, as well as recommend improvement strategies in boosting production efficiency. Based on the identification results, two dominant wastes occurred in the form of defects and waiting. The defect and scrap portions were prevalent in gum rosin drops, flakes, brushed dust and products that did not fulfill color and size specifications at 63.72 kg/shift that equal to 2,08% scrap rate per shift. Meanwhile, waiting waste refers to work-in-process (WIP) on Oleo Pine Resin (OPR) storage and delay interval for a complete sampling process. The WIP circumstance was also observed at the packaging workstation. Furthermore, repairing tank leaks, allocating special workers to flaking workstations, extending workers’ supervision, combining flake cooling and transportation processes, procuring cooling conveyors and increasing the quantity of esterification reactors were recommendations for optimum production. These proposed activities have the capacity to enhance the process cycle efficiency (PCE) value from 4.65 to 6.34%.

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“…Selanjutnya untuk memilih seven value stream mapping tools yang tepat untuk masing-masing waste kritis dapat menggunakan value stream analysis tool (Garside & Baya'sud, 2008). Armyanto et al ( 2020 Failure Mode Effect Analysis (FMEA) merupakan analisa yang dilakukan untuk menemukan efek apa saja yang dapat berpotensi membuat kegagalan pada suatu produk atau proses produksi (Hasanah et al, 2020 Berdasarkan waste kritis yang diperoleh dari WAM dan detailed waste dari value stream mapping tools, maka identifikasi dan penentuan prioritas mode kegagalan dari masing-masing detailed waste dilakukan dengan menggunakan FMEA. Selanjutnya kami memberikan usulan perbaikan berdasarkan mode kegagalan yang memiliki nilai RPN tertinggi pada masing-masing detailed waste.…”

Section: Pendahuluanunclassified

Penerapan Lean Manufacturing untuk Meminimasi Waste Percetakan Box

Krisnanti¹,

Garside²

2022

INTECH

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CV. Aneka Grafika merupakan perusahaan yang bergerak dalam bidang percetakan box. Berdasarkan hasil survey lapangan terdapat beberapa waste pada perusahaan tersebut diantaranya defect pada setiap tahapan proses, penumpukan produk setengah jadi di area kerja dan waktu perpindahan material yang lama. Tujuan dari penelitian ini adalah meminimasi waste yang terjadi di lantai produksi CV. Aneka Grafika dengan menerapkan lean manufacturing. Langkah penelitian meliputi identifikasi jenis waste kritis menggunakan metode waste assessment model, pemilihan value stream mapping tool dengan VALSAT, pemetaan aktivitas dan jenis defect dengan value stream mapping tool terpilih untuk menentukan detailed waste, identifikasi penyebab dari detailed waste menggunakan fishbone diagram, penentuan prioritas mode kegagalan dan penyebab kegagalan dengan menggunakan Failure Mode and Effect Analysis, dan pemberian usulan perbaikan berdasarkan mode kegagalan yang memiliki nilai risk priority number tertinggi. Hasil dari menggunakan waste assessment model didapatkan bahwa jenis waste kritis adalah adalah defect (18,02%), transportation (16,14%), dan unnecessary motion (15,06%) Beberapa usulan perbaikan yang direkomendasikan ke perusahaan untuk meminimasi waste adalah: penetapan Standard Operating Procedure (SOP) pada proses kontrol mesin cetak, relayout lantai produksi, dan pemasangan visual display.

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Penerapan Lean Manufacturing dengan Metode Takt Time dan FMEA untuk Mengidentifikasi Waste pada Proses Produksi Steril PT.XYZ

Cited by 9 publications

References 0 publications

Profit comparison analysis in production system simulation based on lean principles to achieve sustainable manufacturing

Profit comparison analysis in production system simulation based on lean principles to achieve sustainable manufacturing

The Analysis of Lean Manufacturing in Waste Reduction During Rosin Ester Production at PT XYZ

Penerapan Lean Manufacturing untuk Meminimasi Waste Percetakan Box

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