Usulan perbaikan proses produksi basko TN-Basreng dengan simulasi pada PT Berkat Langgeng Lestari

Matthew, Anthony (2024) Usulan perbaikan proses produksi basko TN-Basreng dengan simulasi pada PT Berkat Langgeng Lestari. Bachelor thesis, Universitas Pelita Harapan.

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Abstract

Persaingan yang semakin ketat dalam dunia industri makanan menuntut perusahaan untuk memiliki kemampuan bersaing guna memenuhi permintaan pasar. PT Berkat Langgeng Lestari, sebagai perusahaan manufaktur bakso di Kota Bekasi, melalui observasi awal, mengidentifikasi beberapa pemborosan, seperti adanya bakso cacat dan penumpukan work in process (WIP). Untuk mengatasi hal ini, dilakukan penelitian lebih lanjut guna mengidentifikasi dan menganalisis pemborosan di lantai produksi, merancang future state map, serta melakukan uji coba usulan perbaikan melalui simulasi. Penelitian ini menerapkan teori utama lean untuk menghilangkan pemborosan yang menjadi beban pada sistem, serta simulasi untuk menguji usulan perbaikan. Objek penelitian ini adalah Bakso TN-Basreng, yang merupakan jenis bakso dengan penjualan terbanyak, mencapai 39,63% dari total penjualan. Saat ini, total cycle time adalah 4951,27 detik dan total lead time sebesar 5507,50 detik. Berdasarkan perhitungan, didapatkan takt time sebesar 960 detik/batch dan proses pengeringan menjadi bottleneck karena waktu prosesnya melebihi takt time. Pada kondisi saat ini, perusahaan memiliki waktu aktivitas value added sebesar 4872,06 detik, necessary non-value added sebesar 635,44 detik, dan tidak ada non-value added. Process cycle efficiency (PCE) saat ini sebesar 88,46%, yang dapat dikatakan sudah lean, karena nilai tersebut melebihi 30%. Ditemukan pemborosan pada defect, inventory, dan motion di lantai produksi, dengan rata-rata defect/batch sebesar 1,38%, dan waktu tunggu yang cukup lama di stasiun kerja packing, yakni sebesar 25,34 menit. Melalui observasi langsung dan simulasi, teridentifikasi adanya penumpukan pada stasiun kerja pengeringan yang disebabkan oleh ketidakmampuan stasiun kerja packing dalam menanggapi volume bakso dari stasiun kerja pengeringan. Pemborosan motion terjadi pada stasiun kerja pengadukan, di mana operator harus mengambil adonan yang meluap dari bowl cutter dengan waktu rata-rata 16,68 detik/batch. Berdasarkan usulan perbaikan, penambahan 1 operator di stasiun kerja packing menjadi 4 operator mampu mengurangi rata-rata waktu tunggu di rak packing sebesar 87,62% dan meningkatkan total output sebesar 19,15%. / Increasingly fierce competition in the food industry requires companies to have the ability to compete to meet market demand. PT Berkat Langgeng Lestari, as a meatball manufacturing company in Bekasi City, through initial observations, identified several wastes, such as the presence of defective meatballs and the accumulation of work in process (WIP). To overcome this, further research was conducted to identify and analyze waste on the production floor, design a future state map, and test the proposed improvements through simulation. This research applies the main lean theory to eliminate waste that becomes a burden on the system, as well as simulation to test the proposed improvements. The object of this research is Bakso TN-Basreng, which is the type of meatball with the most sales, reaching 39.63% of total sales. Currently, the total cycle time is 4951.27 seconds and the total lead time is 5507.50 seconds. Based on the calculation, the takt time is 960 seconds/batch and the drying process becomes a bottleneck because the process time exceeds the takt time. In the current condition, the company has a value-added activity time of 4872.06 seconds, necessary non-value added of 635.44 seconds, and no non-value added. The current process cycle efficiency (PCE) is 88.46%, which can be said to be lean, because this value exceeds 30%. Defects, inventory, and motion waste were found on the production floor, with an average defect/batch of 1.38%, and a long waiting time at the packing workstation of 25.34 minutes. Through direct observation and simulation, it was identified that there was a buildup at the drying workstation caused by the inability of the packing workstation to respond to the volume of meatballs from the drying workstation. Waste of motion occurs at the stirring workstation, where the operator must pick up the overflowing dough from the bowl cutter with an average time of 16.68 seconds/batch. Based on the proposed improvements, the addition of 1 operator at the packing workstation to 4 operators can reduce the average waiting time at the packing rack by 87.62% and increase the total output by 19.15%.

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