IDENTIFIKASI & ELIMINASI NON-VALUE ADDED ACTIVITIES PADA STASIUN KERJA PACKING KARDUS PRODUK MAKANAN RINGAN (Studi Kasus PT XYZ)

Abstract

Abstrak

Non-Value Added (NVA) Activities adalah aktivitas yang tidak menciptakan atau menambahkan value bagi Produk atau jasa serta dapat dihindari dan tidak dibutuhkan dalam proses transformasi material atau informasi termasuk pada PT XYZ, salah satu perusahaan manufaktur makanan ringan di Indonesia. Masalah yang peneliti temukan pada stasiun kerja packing kardus Produk Makanan Ringan A gram pada PT XYZ adalah Operator menghabiskan waktu 3075,168 detik dari 9174,488 detik untuk melakukan NVA Activities yang menyebabkan peningkatan waktu siklus. Pemecahan masalah dilakukan dengan identifikasi persentase Value Added (VA), Necessary Non-Value Added (NNVA), dan NVA Activities dengan Process Activity Map (PAM), dan identifikasi akar penyebab NVA Activities serta rekomendasi perbaikan dengan Failure Mode and Effect Analysis (FMEA). Berdasarkan PAM ditemukan bahwa persentase VA Activities adalah 61.279%, NNVA Activities adalah 5.202%, dan NVA Activities 33.519% serta aktivitas yang paling berkontribusi terhadap persentase NVA Activities adalah memperbaiki automatic sauce feeder dengan kontribusi 47.335% dari seluruh NVA Activities. Berdasarkan FMEA ditemukan bahwa akar penyebab munculnya aktivitas tersebut adalah silinder yang tidak sinkron dengan nilai Risk Priority Number (RPN) 20. Terdapat juga faktor lain yaitu saus sambal tomat cup tersangkut dengan nilai RPN 16, dan saussambal tomat cup habis dengan nilai RPN 10. Rekomendasi perbaikan yang diperoleh berdasarkan hasil FMEA dan observasi lanjutan adalah perawatan dan perbaikan pada saluran angin dan komponen elektronik silinder, perubahan bentuk kawat besi pada pangkal linear track, dan peningkatan sensitivitas sensor isi ulang bowl otomatis. Dengan asumsi bahwa rekomendasi perbaikan efektif, persentase NVA Activities berpotensi berkurang menjadi 17.652%.

Kata Kunci: Lean Manufacturing; Non-Value Added Activities (NVA); Process Activity Mapping (PAM); Failure Mode and Effect Analysis (FMEA)

Abstract

Identification & Elimination of Non-Value Added Activities on Snack Cardboard Box Packing Station (A Study Case on PT XYZ) Non-Value Added (NVA) Activities are activities that do not create or add value to products or services and can be avoided while also not essential to the transformation of material and information, including within PT XYZ, one of Indonesia’s snack manufacturing companies. The problem that the researcher found within the A gram snack cardboard box packing work station is how the Operator spends 3075.168 s out of 9174.488 s to do NVA Activities that increase cycle time. To solve the problem, the identification of Value Added (VA), Necessary Non-Value Added (NVA), and NVA percentage with Process Activity Map (PAM) and the identification of NVA Activities’ root cause and improvement recommendations with Failure Mode and Effect Analysis (FMEA) are done. Based on the PAM, it is found that the percentage of VA Activities are 61.279%, NNVA Activities are 5.202%, and NVA Activities are 33.519% and the activity that contributed the most to the NVA Activities percentage is repairing the automatic sauce feeder which contributed 47.335% out of the total of NVA Activities percentage. Based on FMEA, it is found that the root cause of why we need to repair the automatic sauce feeder constantly 2 is that the cylinder parts of the machine are unsynchronized which got the Risk Priority Number (RPN) value of 20. There are also other factors that contributed such as chili-tomato cup sauces that got stuck which got the RPN value of 16 and depletion of chili-tomato cup sauces in the machine which got the RPN value of 10. Improvement recommendations that are earned through FMEA and further observations are maintenance and reparation of the cylinder’s air tube and electrical components, changing the shape of the machine’s linear track, and increasing of the bowl’s automatic refill sensors. Assuming that the improvement recommendations are effective, the NVA percentage have the potential to be decreased into 17.652%.

Keywords: Lean Manufacturing; Non-Value Added Activities (NVA); Process Activity Mapping (PAM); Failure Mode and Effect Analysis (FMEA)