PENDEKATAN LEAN MANUFACTURING PADA LINI PRODUKSI ROMA KELAPA DENGAN METODE VALSAT PADA PT. MAYORA INDAH Tbk.

Abstract

ABSTRAK

PT. Mayora Indah Tbk. merupakan perusahaan pangan yang menghasilkan produk makanan dan minuman yang berbasis konsumen Pasar Dalam Negeri dan Pasar Luar Negeri. Salah satu produk biskuit PT. Mayora Indah Tbk. Divisi Biskuit Jayanti yaitu Roma Kelapa. Pada proses pembuatan biskuit Roma Kelapa melewati beberapa tahap mulai dari Central Kitchen, Mixing, Tilting, Molding, Oven, Cooling, dan Packing. Dalam pemenuhan kebutuhan konsumen, perusahaan menerapkan sistem make to order. Namun pada proses produksi, total produksi tidak sesuai dengan perencanaan dimana jumlah produksi aktual lebih sedikit dari perencanaan yang disebabkan banyaknya produk reject. Produk reject terbesar disebabkan oleh mesin oven sebanyak 198.832,2 ton dan mesin packing sebanyak 692.383,7 ton selama 8 bulan terakhir. Untuk mengurangi jumlah produk reject perusahaan perlu meningkatkan produktivitas dengan menerapkan konsep Lean Manufacturing. Konsep Lean Manufacturing merupakan metode pengoptimalan performansi dari proses produksi karena mampu mengidentifikasi, menganalisa, dan memberikan solusi perbaikan. Lean berfokus pada peningkatan efisiensi tanpa mengurangi efektivitas, seperti mengeliminasi waste (pemborosan). Dalam melakukan analisis penyebab pemborosan dilakukan metode VALSAT. Pada metode VALSAT digunakan 2 mapping tools yaitu process activity mapping dan quality fillter mapping. Pada process activity mapping didapatkan nilai kegiatan bernilai tambah (Value Added) sebesar 13.13%, kegiatan tidak bernilai tambah (Non Value Added) sebesar 10.22%, dan kegiatan tidak bernilai tambah tetapi diperlukan (Needed Non Value Added) yaitu sebesar 76.32%. Perbaikan yang dapat diberikan pada pemborosan Process Activity yaitu memperpendek jalur transfer (konveyor) biskuit.

ABSTRACT

PT. Mayora Indah Tbk. is a food company that produces food products and consumer-based beverages Domestic Market and Overseas Markets. One biscuit products PT. Mayora Indah Tbk. Biscuits division that Rome Coconut Jayanti. In the process of making biscuits Rome Coconut go through several stages starting from the Central Kitchen, Mixing, Tilting, Molding, Oven, Cooling, and Packing. In fulfillment of the needs of consumers, the company implemented the system make to order. But in the process of production, total production does not correspond to the actual production planning where fewer number of planning because many reject product. The rejection of products due to the oven as much as 198,832.2 ton machine and packing machine as 692,383.7 tons over the last 8 months. To reduce the number of reject products companies need to increase productivity by applying the concept of Lean Manufacturing. The concept of Lean Manufacturing is a method of optimizing the performance of the production process because it can identify, analyze, and provide repair solutions. Lean focuses on improving efficiency without compromising effectiveness, such as eliminating waste (waste). In analyzing the causes of wastage carried VALSAT method. In the second method is used VALSAT mapping tools that process mapping and quality fillter activity mapping. In the process mapping activity obtained value-added value activities (Value Added) of 13:13%, not value-added activities (Non Value Added) of 10:22%, and value-added activity but needed (Needed Non Value Added) is equal to 76.32%. Improvements that can be given to waste is Process Activity shorten transfer path (conveyor) biscuits.