Analisis Integrasi Lean dan Six Sigma untuk Mengeliminasi Waste Pada Proses Produksi Batu Bata Di PT Family

Abstract

Penelitian ini dilakukan di PT Family yang memproduksi batu bata dengan tujuan mengidentifikasi dan mengurangi pemborosan pada proses produksi. Metode yang digunakan adalah integrasi Lean dan Six Sigma melalui tahapan DMAIC. Hasil pengukuran menunjukkan Manufacturing Lead Time (MLT) sebesar 8.854,74 menit dengan Process Cycle Efficiency (PCE) 49. Dari total waktu tersebut, aktivitas bernilai tambah tercatat 4.389,34 menit, aktivitas yang tidak bernilai tambah namun diperlukan 4.432,70 menit, dan aktivitas tanpa nilai tambah 32,70 menit. Analisis Six Sigma menunjukkan tingkat sigma proses pengeringan 3,63 dengan DPMO 17.000 dan pembakaran 3,34 dengan DPMO 32.000, keduanya masih di bawah standar enam sigma. Perbaikan dilakukan dengan menghilangkan aktivitas transportasi berulang, mengurangi waktu proses, serta memperbaiki tata letak. Hasil perbaikan mampu merampingkan jumlah proses dari 15 menjadi 12 langkah, sehingga efisiensi meningkat dan pemborosan berkurang. Penelitian ini membuktikan Lean Six Sigma efektif untuk mengurangi waste, menekan variasi, dan meningkatkan kualitas produksi batu bata. This research was conducted at PT Family, a brick manufacturer, with the aim of identifying and reducing waste in the production process. The method used was the integration of Lean and Six Sigma through the DMAIC stages. The measurement results showed a Manufacturing Lead Time (MLT) of 8,854.74 minutes with a Process Cycle Efficiency (PCE) of 49. Of the total time, value-added activities were recorded at 4,389.34 minutes, non-value-added activities but necessary at 4,432.70 minutes, and non-value-added activities at 32.70 minutes. Six Sigma analysis showed a sigma level of 3.63 for the drying process with a DPMO of 17,000 and 3.34 for firing with a DPMO of 32,000, both of which were still below the six sigma standard. Improvements were made by eliminating repetitive transportation activities, reducing process time, and improving the layout. The results of the improvements were able to streamline the number of processes from 15 to 12 steps, thereby increasing efficiency and reducing waste. This research proves that Lean Six Sigma is effective in reducing waste, reducing variation, and improving the quality of brick production.