Reduksi Waste dengan Pendekatan Lean Manufacturing Menggunakan Metode Value Stream Mapping (VSM) dan Failure Mode and Effect Analysis (FMEA) pada PT Pabrik Es Siantar

Abstract

PT Perusahaan Es Siantar is a manufacturing company which operates in the field of processing carbonated drinks which are labeled "Cap Badak". The problem faced by the company is that there is too much waste such as defects and waiting times in its production activities. The aim of this research is to identify and eliminate non-value added activities in the production process using the Lean Manufacturing approach and the Value Stream Mapping method and to provide suggestions for improvements using the Failure Mode Effect Analysis method. Based on the results of observations and measurements, there are 19 activities of which there are 3 non-value added time activities, namely 47,75 minutes, manufacturing lead time of 512,84 minutes, process cycle efficiency level of 76,38% and process velocity of 0.030 processes/hour. Then elimination was carried out on 3 non-value added activities and the results obtained were an improvement in the non-value added time value of 0, manufacturing lead time of 465,08 minutes, process cycle efficiency level of 84,23% and process velocity of 0.025 processes/hour. Based on the results of analysis using FMEA, it is known that the RPN value for each waste is waste waiting for filling bottles of 448 with the source of the cause being the machine, waste waiting for making the product expiry date of 216 with the source of the cause being the method, and waste defect of 192 with the source of the cause namely the machine. To reduce waste, the proposed improvement is to carry out a challenge test on the trimix machine before running, regular monitoring, improving troubleshooting and operational skills for each operator.