Upaya Mengeliminasi Waste dan Mengurangi Kecacatan Produk Snack Balado dengan Lean Six Sigma pada CV XYZ

Abstract

CV XYZ operates in the food industry, producing snacks such as balado chips. Based on observations of the balado chip production process, issues of waste in the form of waiting time and defects were identified. The aim of this study is to identify and eliminate non-value-added activities and reduce defects in balado chips using Lean Six Sigma (DMAIC) and Process Activity Mapping, and to provide improvement proposals. Measurements found 3 non-value-added activities totaling 114.20 minutes, with a manufacturing lead time of 334.20 minutes, a process cycle efficiency of 54.24%, and a process velocity of 0.010 processes/hour. The types of defects analyzed include breakage, thickness, and clumping. After eliminating the 3 non-value-added activities, the manufacturing lead time was reduced to 219.75 minutes, process cycle efficiency increased to 82.49%, and process velocity increased to 0.084 processes/hour. With the implementation of the proposed improvements, the Defect Per Million Opportunity (DPMO) decreased from 25,667 units to 17,103 units, and the sigma level increased from 3.44 to 3.62. This indicates that the improvements in the balado chip production process successfully enhanced quality by reducing DPMO and achieving a higher sigma level, reflecting lower process variation and improved product quality. The proposed improvements include designing standard operating procedures for the pressing, cutting, and frying stations, conducting regular checks on raw material stock, optimizing material handling, maintaining production machines and equipment, and routinely supervising operators at each production station