Pengurangan Waste untuk Meningkatkan Kualitas Bubuk Teh dengan Pendekatan Lean Six Sigma

Abstract

The rapid development of the industrial world today makes competition more competitive, especially in the manufacturing industry which requires companies to continue to produce quality products in order to compete with other companies in the same field. PT XYZ is an agro-industrial company engaged in the tea powder processing business where the products produced are tea powder which is divided into grade I, grade II, and grade III. The research was conducted on the tea powder production process which experienced waste problems in the form of waiting activities in the production process, unnecessary movement activities carried out by operators and defects. Based on observations made in the tea powder production process, there is waste in the form of product defects with an average percentage of 5.30% where the company wants the product defect tolerance limit to be below 1%. The total time of non-value added waiting activity is 19.62 minutes and nonvalue added motion activity is 66.14 minutes. The purpose of this study is to identify and calculate the time of value-added, necessary non-value-added, and non-valueadded activities, eliminate non-value-added activities and provide suggestions for improvements to improve the quality of tea powder. The method used to solve the problem in this research is lean six sigma. Lean Six Sigma is a combination of lean and six sigma concepts using the DMAIC method (Define, Measure, Analyze, Improve, and Control). The proposed improvements use the FMEA method with Risk Priority Number (RPN) assessment. The proposed improvements are made on the identification of the causal factors of methods, people, and machines. From the calculation results obtained an increase in sigma level from 3.60 to 4.41. In addition, it also eliminates non-value added activities as many as 14 activities so that there is a reduction in manufacturing lead time by 85.76 minutes.