Penerapan Lean Manufacturing Untuk Meminimasi Pemborosan Waktu Pada Studi Kasus Home Industri Sofa Pak Suparjo

Abstract

Sofa Home Industri Pak Suparjo merupakan UMKM yang bergerak dibidang usaha furniture yang memproduksi sofa. Produk sofa memiliki beberapa tahapan proses produksi namun dalam proses pembuatan produk yang cukup banyak terjadi beberapa jenis pemborosan. Dapat diketahui total waktu produksi adalah 5.760 menit (empat hari) dengan beberapa pemborosan (waste) yang terjadi didalamnya yaitu pemindahan proses produksi (2.880 menit), menunggu bahan baku (2.880 menit), defect (9 set). Oleh karena itu, perlu diidentifikasi pemborosan dan menganalisa penyebab pemborosan tersebut untuk meningkatkan produktivitas dengan menerapkan lean manufacturing pada proses produksi sofa menggunakan value stream mapping untuk mengetahui aliran produk dan aliran informasi yang mendukung aktivitas lain dan juga untuk menghilangkan pemborosan serta mencari penyebab terjadinya pemborosan tersebut dengan fishbone diagram. Berdasarkan hasil current value stream mapping mengetahui cycle time 2925,9 menit lead time 1454,02 menit, value added 1523,17 menit. Setelah dilakukan process activity mapping didapatkan hasil current value stream mapping future state jumlah cycle time menurun menjadi 2818,14 menit, lead time menurun menjadi 1.346,26 menit dan juga penjabaran suatu masalah dari fishbone diagram tersebut yaitu faktor man (kurang cekatan), measurement (pemotongan kayu yang berulang), method (potongan kayu tidak rata), material (ketebalan kayu tidak sesuai). Adapun rekomendasi perbaikan untuk meminimasi pemborosan berupa Standard Operation Procedure dan menerapkan 5S juga 5W+1H. Pak Suparjo's Sofa Home Industry was a micro, small, and medium enterprise engaged in the furniture business that produced sofas. The sofa product has several stages of the production process; however, during the production process, which involved a considerable quantity, several types of waste occurred. It was known that the total production time was 5,760 minutes (four days) with several types of waste occurring, namely the transfer of the production process (2,880 minutes), waiting for raw materials (2,880 minutes), defect (9 sets). Therefore, it was necessary to identify the waste and analyze the causes of the waste to improve productivity by applying lean manufacturing to the sofa production process using value stream mapping to identify the product flow and information flow that supported other activities, as well as to eliminate waste and find the causes of the waste using a fishbone diagram. Based on the results of the current value stream mapping, the cycle time was 2,925.9 minutes, the lead time was 1,454.02 minutes, and the value added was 1,523.17 minutes. After conducting process activity mapping, the results of the future state current value stream mapping showed the total cycle time decreased to 2,818.14 minutes, the lead time decreased to 1,346.26 minutes, and also the elaboration of a problem from the fishbone diagram was the factors of man (lack of agility), measurement (repeated wood cutting), method (uneven wood cuts), material (inappropriate wood thickness). The recommendations for improvement to minimize waste were in the form of a Standard Operating Procedure and the implementation of 5S and 5W+1H.