Penerapan Lean Manufacturing Menggunakan Prinsip Kaizen dan Value Stream Mapping untuk Mereduksi Waste pada PT Perkebunan Nusantara II Unit Pabrik Kelapa Sawit (PKS) Pagar Merbau

Abstract

Lean manufacturing is a concept used to streamline production which is oriented towards reducing waste that occurs in production so that processes can run effectively and efficiently. This research was conducted to identify and reduce waste and non-value added activities that occur in Crude Palm Oil (CPO) production process at Palm Oil Mill Pagar Merbau PT Perkebunan Nusantara II. The research uses the application of lean manufacturing based on Kaizen principles with the Plan-Do-Check-Action cycle. Dominant waste identification is carried out by calculating the Borda Count Method, so that 3 types of dominant waste that occur in Pagar Merbau PKS are obtained, namely waste motions with a weight of 0.3, followed by waste processes and waste delays which generally occur due to operator errors, tool design, and methods less efficient work. By using the Process Activity Mapping (PAM) tools selected based on calculations using the Value Stream Analysis Tools (VALSAT), it is known that the total actual production cycle time is 52,947.6 seconds, where Value Added activities are 61%, Necessary Non Value Added are 26.01% and Non Value Added 12.99%, with a Process Cycle Efficiency value of 66.46%. Therefore, identifying the root cause of the problem with a fishbone diagram is then given a proposed improvement plan using the 5W+1H method. After the repairs were carried out, checking was carried out with the proposed Process Activity Mapping (PAM), so that a decrease in the CPO production process time was obtained to 36,467 seconds, where Value Added activities experienced an increase of 29.5%, Necessary Non Value Added decreased 19.3%, and Non Value Added decreased by 10.2%, Process Cycle Efficiency value became 90.5% with an increase in average efficiency value of 29.07% to 93.81