EFISIENSI OPERASIONAL PERGUDANGAN MENGGUNAKAN METODE VALUE STREAM MAPPING UNTUK MEMINIMASI WASTE (STUDI KASUS: PT PETROKIMIA GRESIK

Abstract

Abstrak

PT Petrokimia Gresik merupakan perusahaan industri manufaktur yang bergerak dalam memproduksi pupuk dan juga non-pupuk sejak tahun 1972. Penelitian ini berfokus terhadap produk pupuk yang berada di Gudang Urea II. Sebelum adanya proses pengiriman, produk-produk yang dihasilkan harus melewati proses packing sebelum dimuat (loading) menggunakan truk untuk dikirimkan kepada konsumen. Dalam proses packing, ditemukan adanya beberapa permasalahan, mulai dari mesin packing yang cukup sering berhenti saat proses packing, banyaknya pupuk yang gagal muat karena banyaknya pupuk inbags yang rusak saat dilakukan pemuatan, dan juga para pekerja manusia yang masih belum memahami SOP mengenai proses packing sebelum dilakukan pemuatan. Tujuan penelitian ini yaitu untuk mengidentifikasi waste yang ditemukan pada proses packing, mengidentifikasi aktivitas-aktivitas yang bernilai Non Value Added, Value Added, dan Necessary Non Value Added, dan merancang perbaikan terhadap waste yang teridentifikasi menggunakan Value Stream Mapping. Berdasarkan hasil yang ditemukan, jenis waste yang teridentifikasi yaitu waiting time dan defects. Selanjutnya, aktivitas aktivitas yang bernilai sebagai Non Value Added memiliki total waktu sebesar 70% dari total waktu siklus, Value Added sebesar 4% dari total waktu siklus, dan Necessary Non Value Added sebesar 26% dari total waktu siklus. Selanjutnya, beberapa rekomendasi perbaikan yang diberikan yaitu rutin mengganti jarum mesin jahit packing, menetapkan standar jumlah pupuk rusak, memberikan evaluasi kepada operator mengenai kinerja, dan melakukan training secara rutin terhadap operator packing. Adanya rancangan Future Value Stream Mapping juga turut memberikan kontribusi dalam penurunan total waktu siklus sebesar 25% sehingga proses packing akan menjadi lebih cepat dan efisien.

Kata kunci: Non Value Added, Value Added, Lean Manufacturing, Value Stream Mapping

Abstract

[Title:Efficiency of Warehouse Operational based on Lean Manufacturing Approach using Value Stream Mapping Methods to Minimize Waste (Case Study: PT Petrokimia Gresik)] PT Petrokimia Gresik is an industrial manufacturing company engaged in producing fertilizers and also non-fertilizers since 1972. This research focuses on fertilizer products in Urea Warehouse II. Before the shipping process, the products produced must pass the packing process before loading using a truck to be sent to consumers. In the packing process, several problems were found, from packing machines that stopped quite often during the packing process, the number of fertilizers that failed to load due to the large number of fertilizer inbags were damaged during loading, and also human workers who still did not understand the procedure regarding the packing process before loading. The purpose of this research is to identify waste found in the packing process, identify activities that are Non Value Added, Value Added, and Necessary Non Value Added, and design improvements to the identified waste using Value Stream Mapping. Based on the results found, the types of waste identified are waiting time and defects. Furthermore, activities valued as Non Value Added have a total time of 70% of the total cycle time, Value Added of 4% of the total cycle time, and Necessary Non Value Added of 26% of the total cycle time. Furthermore, some of the improvement recommendations given are routinely replacing the needle of the packing sewing machine, setting a standard for the amount of damaged fertilizer, providing evaluations to operators regarding performance, and conducting regular training for packing operators. The Future Value Stream Mapping design also gives a contributes to decrease in total cycle time by 25% so that the packing process will become faster and more efficient.

Keywords: Non Value Added, Value Added, Lean Manufacturing, Value Stream Mapping