Reduksi Lead Time melalui Pendekatan Lean Manufacturing pada Sabun Bar Transparan “X” di PT XYZ Kota Bogor

Abstract

Panjangnya lead time produksi sabun bar transparan "X" di PT XYZ yang melebihi standar melatarbelakangi penelitian ini. Penelitian ini bertujuan menganalisis kondisi aktual, mengidentifikasi waste, menyusun usulan perbaikan lean manufacturing pada proses extruder hingga finishing, serta menunjukkan peningkatan efisiensinya. Metode yang digunakan adalah VSM, PAM, Pareto, 5 Whys, One Piece Flow, dan line balancing. Hasil menunjukkan Process Cycle Efficiency (PCE) awal hanya 34,86% dengan lead time 61 jam 5 menit 30 detik akibat dominasi waste waiting time (90,6%) dalam sistem batch flow. Usulan perbaikan dilakukan dengan mengubah sistem menjadi One Piece Flow (per box), menggabungkan stasiun extruder dan cutting, menambah mesin stamping, serta merekayasa transportasi box. Hasilnya, lead time tereduksi menjadi 18 jam 2 menit 38 detik dan PCE meningkat signifikan sebesar 37,23% menjadi 72,09%, Penelitian ini membuktikan transisi ke One Piece Flow efektif mereduksi lead time dan meningkatkan efisiensi.

The excessive production lead time of transparent bar soap "X" at PT XYZ serves as the background for this study. This research aims to analyze actual conditions, identify wastes, propose lean manufacturing improvements from the extruder to finishing, and demonstrate its efficiency enhancement. Methods used include VSM, PAM, Pareto, 5 Whys, one-piece flow, and line balancing. Results showed the initial PCE was only 34.86%, with a lead time of 61 hours 5 minutes 30 seconds due to dominant waiting time waste (90,6%) in the batch flow system. The proposed improvement shifts the system to a one-piece flow (per box), combine extruder and cutting stations, adds a stamping machine, and re-engineers box transportation. Consequently, lead time reduced to 18 hours 2 minutes 38 seconds, and PCE increased significantly by 37,23% to 72,09%. This study proves that transitioning to a one-piece flow effectively reduces lead time and enhances efficiency.