ANALISIS JALUR PRODUKSI KASTOR DENGAN VALUE STREAM MAPPING DI PT MEGA ANDALAN RODA DAN KASTOR (MARK)

SUWANTI ASTUTI, Kuncoro Harto Widodo, Dr., M.Eng

2017 | Tesis | S2 Manajemen

PT Mega Andalan Roda dan Kastor adalah perusahaan manufaktur yang memproduksi berbagai jenis roda dan kastor khususnya kastor 5 inch Double Wheel untuk memenuhi kebutuhan produk Hospital Equipment milik PT Mega Andalan Kalasan. Sebagai perusahaan yang berkembang, PT Mega Andalan Roda dan Kastor perlu untuk terus-menerus meningkatkan kinerja produktivitasnya dan meningkatkan keuntungan sebesar-besarnya dengan berusaha menurunkan biaya, meningkatkan kualitas, dan tepat waktu dalam pengiriman ke pelanggan. Kesemuanya itu dapat dicapai dengan cara menghilangkan waste. Penelitian ini dilakukan di PT Mega Andalan Roda dan Kastor, bertujuan untuk mengidentifikasi waste yang terjadi berdasarkan konsep Lean Manufacturing, serta penyebab terjadinya waste dan memberikan rekomendasi perbaikan. Value Stream Mapping digunakan untuk mengetahui gambaran proses produksi di bagian assembling secara umum. Waste diidentifikasi dengan menggunakan kuesioner dan metoda BORDA. Waste yang terpilih kemudian dianalisis dengan Value Stream Analysis Tools (VALSAT) dan Fish-bone Diagram untuk mendapatkan sub waste dan penyebabnya. Hasil penelitian menunjukkan bahwa waste yang paling dominan terjadi adalah waiting, defect, dan inappropriate processing. Waiting waste sangat berkaitan dengan waktu tunggu yang terjadi setelah proses assembling sebelum di inspeksi akhir oleh bagian QC. Perusahaan disarankan untuk melakukan penggabungan proses inspeksi dengan assembling sehingga dapat menghilangkan waktu tunggu dan jumlah barang di WIP. Pemborosan Defect dan pemborosan inappropriate processing sangat berkaitan dengan barang dari vendor yang belum memenuhi spesifikasi yang ditentukan akibatnya perusahaan harus memproses ulang atau melakukan rework. Oleh karena itu perusahaan disarankan untuk mendorong perusahaan vendor menghasilkan kualitas produk yang sesuai.

Be cognizant that PT Mega Andalan Roda and Kastor is as a manufacturing company that produces various types of wheels and castors-especially 5 inch double wheel castor in order to fulfill of Hospital Equipment products needs owned by PT Mega Andalan Kalasan indeed. Well known as a growing company, PT Mega Andalan Roda and Kastor needs to continuously improve its productivity performance and maximize profits as well by trying to reduce both cost, improve quality, and even on time delivery to the customers indeed. Those all can be reached by omitting waste only. This research was conducted by PT Mega Andalan Roda and Kastor, consideration aiming to identify the waste which occurred based on Lean Manufacturing concept, as well as any cause of waste and even gave such recommendation improvement. Here Value Stream Mapping is used to identify the description of the production process in the assembling section in general manner. Those waste was identified using questionnaire and BORDA method. Base on the selected wastes are analyzed with Value Stream Analysis Tools (VALSAT) and Fishbone Diagram in order to obtain sub waste and causes. From the research results showed that the most dominant waste occurred was waiting, defect, and inappropriate processing. Waiting is intense related to the waiting time that occurs after the assembling process before the final inspection by the QC section. The company is advised to merge inspection process with assembling so as to eliminate waiting time and quantity of goods in WIP. Any defect waste is intense related to goods from vendors that have not met the specified specifications so that company is encouraged to conduct the vendor companies to produce conform product quality. Defect waste and inappropriate processing are closely related to goods from vendors that have not met the specified specifications as a result of which the company must reprocess or rework. Therefore companies are encouraged to vendor companies to produce appropriate product quality.

Kata Kunci : Waste, Lean Manufacturing, VSM, VALSAT, BORDA, Fishbone Diagram