Penerapan Lean Manufacturing dalam Mengidentifikasi Waste pada Proses Sampling di PT XYZ

Abstract

PT XYZ menghadapi ketidakseimbangan kapasitas kerja pada bagian Quality Control dengan tingkat okupansi aktual sebesar 91%, melebihi standar perusahaan sebesar 85%, sehingga menyebabkan peningkatan overtime dan penurunan produktivitas analis. Penelitian ini bertujuan mengidentifikasi dan mengeliminasi waste pada proses sampling produk multivitamin menggunakan pendekatan Lean Manufacturing. Metode yang digunakan meliputi Value Stream Mapping (VSM), Process Activity Mapping (PAM), 5 Why Analysis, dan Kaizen 5W+1H. Hasil analisis terhadap empat parameter sampling menunjukkan aktivitas non-value added sebesar 8 jam 51 menit 21 detik (23,7%) dan aktivitas necessary non-value added sebesar 12 jam 29 menit 24 detik (33,4%). Usulan perbaikan berupa penerapan checklist alat, template label, database alat, dan One Point Lesson diprediksi mampu mengeliminasi seluruh aktivitas non-value added menjadi 0 detik serta menurunkan aktivitas necessary non-value added menjadi 10 jam 19 menit 46 detik (46,9%). Perbaikan tersebut menghasilkan penurunan cycle time sebesar 8 jam 1 menit 36 detik sehingga meningkatkan efisiensi proses sampling dan menurunkan overtime pada laboratorium Quality Control PT XYZ.

PT XYZ faces an imbalance in work capacity within the Quality Control department, with an actual occupancy rate of 91%, exceeding the company standard of 85%, thereby increasing overtime and reducing analyst productivity. This study aimed to identify and eliminate waste in the multivitamin product sampling process using a Lean Manufacturing approach. The methods employed included Value Stream Mapping (VSM), Process Activity Mapping (PAM), 5 Why Analysis, and Kaizen 5W+1H. The analysis of four sampling parameters revealed non-value added activities totaling 8 hours 51 minutes 21 seconds (23.7%) and necessary non-value added activities totaling 12 hours 29 minutes 24 seconds (33.4%). Proposed improvements, including equipment checklists, label templates, equipment databases, and One Point Lesson, were predicted to eliminate all non-value added activities to 0 seconds and reduce necessary non-value added activities to 10 hours 19 minutes 46 seconds (46.9%). These improvements resulted in a reduction in cycle time of 8 hours 1 minute 36 seconds, thereby improving sampling process efficiency and reducing overtime in the Quality Control laboratory of PT XYZ.