Lean Manufacturing untuk Meminimasi Lead Time dan Waste agar Tercapainya Target Produksi (Studi kasus: PT. Rollflex Manufacturing Indonesia)
Authors: Moengin Parwadi , Ayunda Nadhifa 
Published: March 2022

Abstrak − PT. Rollflex Manufacturing Indonesia merupakan industri manufaktur yang memproduksi alat material handling yaitu roller conveyor berdasarkan permintaan konsumen sesuai dengan prinsip make to order. Permasalahan yang ditemukan pada lantai produksi PT. Rollflex Manufacturing Indonesia yaitu adanya target produksi yang tidak tercapai pada bulan Mei, Juni, Agustus, September, dan November tahun 2020. Rata-rata target produksi untuk bulan Mei hingga November 2020 yaitu sebesar 742 unit. Target produksi yang tidak tercapai disebabkan karena adanya aktivitas waste (pemborosan) pada lantai produksi yang dapat memperbesar manufacturing lead time. Tujuan penelitian adalah memberikan usulan perbaikan proses produksi roller conveyor dengan menggunakan pendekatan lean manufacturing untuk meminimasi lead time dan waste agar tercapainya target produksi pada PT. Rollflex Manufacturing Indonesia. Metode yang digunakan untuk menyelesaikan masalah adalah lean manufacturing. Lean manufacturing merupakan pendekatan yang bertujuan untuk meminimasi manufacturing lead time dan waste (pemborosan). Identifikasi waste (pemborosan) dapat dilakukan dengan menggunakan peta aliran proses, value stream mapping, dan waste assesment model. Berdasarkan identifikasi waste menggunakan waste assesment model dihasilkan urutan waste dengan persentase terbesar hingga terkecil yaitu motion sebesar 16,95%; transportation sebesar 16,95%; waiting sebesar 16,17%; defect sebesar 16,02%; overproduction sebesar 15,09%; inventory sebesar 12,91%; dan overprocessing sebesar 5,91%. Berdasarkan pemetaan current stream value stream mapping ditemukan waste berupa motion, transportation, dan waiting. Berdasarkan pembagian aktvitas current state value stream mapping dihasilkan manufacturing lead time sebesar 1.525,45 menit; process cycle efficiency sebesar 64,09%; dan target produksi sebesar 748 unit. Perbaikan yang dilakukan untuk meminimasi manufacturing lead time dan waste yaitu dengan menghilangkan aktivitas yang tidak bernilai tambah, penambahan mesin cutting, rancangan 5S, pemindahan meja pengecekan, dan pemisahan aktivitas perakitan dan press. Hasil manufacturing lead time setelah perbaikan yaitu sebesar 1.496,44; process cycle efficiency sebesar 65,33%; target produksi sebesar 808 unit. Abstract − PT. Rollflex Manufacturing Indonesia is a manufacturing industry that produces material handling, namely roller conveyors based on consumer demand following make to order principle. The problems found on the production floor of PT. Rollflex Manufacturing Indonesia is a production target not achieved in May, June, August, September, and November 2020. The average production target for May to November 2020 is 742 units. Production targets that are not achieved are due to waste activity on the production floor, increasing manufacturing lead time. This research aims to propose improving the roller conveyor production process using a lean manufacturing approach to minimize lead time and waste to achieve the production target at PT. Rollflex Manufacturing Indonesia. The method used to solve the problem is lean manufacturing. Lean manufacturing is an approach that aims to minimize manufacturing lead time and waste. Waste identification can be generated using process flow maps, value stream mapping, and waste assessment models. Based on the identification of waste using the waste assessment model, a waste sequence is produced with the largest to the smallest percentage, namely motion at 16.95%; transportation 16.95%; waiting for 16.17%; defect 16.02%; overproduction of 15.09%; inventory of 12.91%; and overprocessing 5.91%. Based on the current stream value stream mapping, it is found that waste is in the form of motion, transportation, and waiting. Based on the distribution of current state value stream mapping activities, the resulting manufacturing lead time is 1,525.45 minutes; process cycle efficiency of 64.09%; and a production target of 748 units. Improvements made to minimize manufacturing lead time and waste are eliminating non-value-added activities, adding cutting machines, designing 5S, moving check tables, and separating assembly and press activities. The results of manufacturing lead time after improvement are 1,496.44; process cycle efficiency of 65.33%; production target of 808 units.