UPAYA PENURUNAN MATERIAL LOSS PADA PROSES PRODUKSI GULA DENGAN MENGGUNAKAN KOMBINASI METODE BUSINESS PROCESS REENGINEERING (BPR) DAN USE-PDSA

MARIANI AGUSTIN, Dr. Ir. Adi Djoko Guritno, MSIE

2013 | Skripsi | TEKNOLOGI INDUSTRI PERTANIAN

Gula merupakan salah satu komoditas strategis yang ketersediaannya selalu dibutuhkan. Saat kondisi dalam negeri menunjukkan produksi gula lebih kecil daripada konsumsi gula maka impor sebagai solusinya, sehingga posisi produsen gula “termanjakan” karena selalu dalam comfort zone. Permasalahan dari sisi off-farm merupakan permasalahan dominan yang dihadapi industri gula Indonesia saat ini. Berbagai permasalahan yang timbul mendorong para pelaku industri gula untuk melakukan usaha peningkatan produksi gula guna memperbaiki kinerja industri gula. mengidentifikasi Penelitian ini bertujuan untuk material loss guna menentukan titik-titik potensial dimana dapat melakukan tindakan perbaikan dalam upaya menurunkan material loss pada proses produksi gula di Pabrik Gula Madukismo. Metode pendekatan yang digunakan adalah kombinasi metode Business Process Reengineering (BPR) dan USE-PDSA (Understand the quality improvement needs, State the quality problem, Evaluate the root cause, Plan the solution, Do the solution, Study the solution result, dan Act to standardize the solutions). Tiga titik potensi terjadinya material loss pada proses produksi gula, yaitu pada ampas, blothong, dan tetes dengan persentase terbesar terjadi pada ampas yaitu sebesar 52,29% dari total loss. Teridentifikasi bahwa sekitar 70% faktor penyebab terjadinya material loss adalah tingkat utilisasi mesin yang tidak memadai. Rekomendasi upaya perbaikan yang dapat dilakukan adalah penjadwalan maintenance mesin berdasarkan pada nilai MTBF-nya, mempersingkat waktu tunggu tebu di cane yard, dan memperketat sistem kontrol jalur kritis proses yaitu pada intensitas pencacahan, penggunaan air imbibisi, dan pemerahan tebu.

Sugar is one of the most strategic commodities which its availability always needed. When the national condition indicate that the sugar production is less than the sugar consumption, the government decide importing sugar as the solution, so the position of the sugar producers are “spoiled” because always in their comfort zone. The off-farm side is the dominant issues faced by the sugar industry in Indonesia today. Because of so many problems happened, the sugar stakeholders are pushed to make sugar production improvement in order to repair the performance of sugar industry. The aim of this research is to identify material loss in order to determine the potential points, so we can do improvement action to reduce material loss in sugar production process in Sugar mill Madukismo. Approached method used in this research is combination between Business Process Reengineering (BPR) and USE-PDSA (Understand the quality improvement needs, State the quality problem, Evaluate the root cause, Plan the solution, Do the solution, Study the solution result, and Act to standardize the solutions). The research result show that material loss occurred in three potential points of sugar production, there are bagasse, filter cake, and molasses, with bagasse as the biggest percentage (52,29% from total loss). It is identified that improperly machine utilization level is the main cause (approximately 70 %) of material losses. The improvement action recommendation consist of maintenance machine scheduling based on MTBF value, decreasing cane waiting time (before processed) in cane yard, and tightening the critical process control system in cane cutting intensity, imbibitions water used, and cane extraction.

Kata Kunci : Industri gula, Material loss, Business Process Reengineering, USE- PDSA