Reduksi Kegiatan Non Value Added dengan Pendekatan Lean Manufacturing Menggunakan Metode Value Stream Mapping (VSM)

Abstract

UMKM As-Li Khas Medan is a microenterprise established in 2012, engaged in the food processing sector, particularly in the production of traditional cookies such as pineapple tarts, skippy cookies, and snow cookies in Medan, North Sumatra. The main problem faced by the enterprise is the presence of waste, such as overprocessing and excessive waiting time during production activities, which may result in the inability to meet market demand. The objective of this study is to eliminate waste and non-value-added activities in the production process by applying Lean Manufacturing and Value Stream Mapping methods, as well as to provide improvement suggestions using the Failure Mode Effect and Critical Analysis (FMECA) method. Based on observations and measurements at UMKM As-Li Khas Medan, there were 28 activities identified, with a total non-value-added time of 74.37 minutes, a manufacturing lead time of 521,08 minutes, a process cycle efficiency (PCE) of 80,89%, and a process velocity of 0,05373 process/hour, After eliminating three non-value-added activities, improvements were achieved by reducing the number of activities to 25, decreasing the non-value-added time to 0,00 minutes, reducing the manufacturing lead time to 446,71 minutes, increasing the process cycle efficiency to 94,36%, and process velocity increased to 0,05596 process/hour, As a result of these improvements, the monthly production output increased from 369,500 units/month to 421,914 units/month, Based on the Failure Mode Effect and Critical Analysis, the criticality level of the overprocessing and waiting waste was classified as unacceptable with a score of 320, 240 and 192, Proposed improvements include: establishing standard operating procedures (SOPs) for production activities, maximizing the capacity of the production area or adding new machines/equipment to ensure smoother production flow, and conducting regular supervision for all workers.