Minimasi Waste dengan Pendekatan Lean Manufacturing dan Line Balancing di Workshop PT X

Abstract

Adanya pemborosan berupa waiting time di workshop PT X akibat ketidakseimbangan antar stasiun kerja pada proses produksi meja kerja, mengakibatkan bottleneck pada keseluruhan aliran produski. Penelitian ini bertujuan mengidentifikasi alur proses produksi menggunakan Value Stream Mapping (VSM), ketidakseimbangan stasiun kerja menggunakan line balancing, proporsi aktivitas berdasarkan ada tidaknya nilai tambah terhadap produk menggunakan Process Activity Mapping (PAM), akar penyebab munculnya pemborosan menggunakan why-why analysis, serta menyusun usulan perbaikan berkelanjutan berdasarkan pendekatan lean manufacturing. Hasil analisis menunjukkan bahwa pada current state VSM, aktivitas VA sebesar 46,63%, NVA sebesar 35,23% dan NNVA sebesar 18,13%. Setelah dilakukan perbaikan, proporsi persentase VA meningkat menjadi 55,90% dan NVA menurun menjadi 24,84%. Menurunnya waiting time juga meningkatkan efisiensi lini produksi dari 71,84% menjadi 76,67%.

Waste in the form of waiting time at PT X’s workshop, resulting from imbalances between workstations in the workbench production process, has caused a bottleneck in the overall production flow. This study aims to identify the production process flow using Value Stream Mapping (VSM), workstation imbalances using line balancing, the proportion of activities based on the presence or absence of value added to the product using Process Activity Mapping (PAM), the root causes of waste using why-why analysis, and to formulate proposals for continuous improvement based on the lean manufacturing approach. Analysis results show that in the current state VSM, VA for 46.63%, while NVA for 35.23% and NNVA for 18.13%. After improvements were implemented, the percentage of VA increased to 55.90% and NVA decreased to 24.84%. The reduction in waiting time also improved production line efficiency from 71.84% to 76.67%.