Usulan Perbaikan Proses Produksi Berbasis Lean Manufacturing untuk Mengurangi Defect Burry pada Produk Body Leg Shield di PT XYZ

Abstract

PT XYZ, sebagai perusahaan manufaktur injeksi plastik untuk komponen kendaraan bermotor, menghadapi masalah defect burry pada produk Body Leg Shield yang berdampak pada tingginya jumlah claim dari customer dan pekerjaan rework. Penelitian ini bertujuan untuk mengidentifikasi titik awal penyebab defect burry dan mengusulkan perbaikan proses menggunakan pendekatan Lean Manufacturing dan Lean Six Sigma. Pemetaan dilakukan melalui penyusunan Current State Mapping (CSM) berdasarkan data aktual dan observasi langsung. Hasil CSM menunjukkan aktivitas non-value added sebesar 78.5% mendominasi waktu proses. Analisis dilakukan menggunakan metode DMAIC. Analisis akar penyebab menunjukkan bahwa defect burry tidak hanya disebabkan oleh aspek teknis mesin, namun juga faktor inspeksi visual dan metode kerja. Output penelitian berupa tiga usulan SOP dan Future State Mapping (FSM) yang menunjukkan perbaikan efisiensi proses, penurunan waktu NVA secara signifikan, serta penguatan kendali mutu.

PT XYZ, a plastic injection manufacturer for motorcycle components, faces a quality issue in the form of burry defects on Body Leg Shield products, resulting in high customer claim rates and additional rework activities. This research aims to identify the root causes of the burry defect and propose process improvements using Lean Manufacturing and Lean Six Sigma approaches. Mapping was conducted through the development of a Current State Mapping (CSM) based on actual process data and field observations. The CSM revealed that non-value added (NVA) activities with 78.5% dominated the total process time. The DMAIC method was used to analyze the problem. Root cause analysis indicated that the burry defect was caused not only by technical issues in the molding process, but also by weaknesses in visual inspection and operator practices. The output includes three proposed Standard Operating Procedures (SOPs) and a Future State Mapping (FSM), showing reduced NVA time and improved quality control.