MINIMASI WASTE DAN USULAN PENINGKATAN EFISIENSI PROSES PRODUKSI MCB (MINI CIRCUIT BREAKER) DENGAN PENDEKATAN SISTEM LEAN MANUFACTURING (DI PT SCHNEIDER ELECTRIC INDONESIA)
Abstract
PT. Schneider Electric Indonesia adalah sebuah perusahaan manufacturing yang berhubungan dengan produksi peralatan elektronik contohnya seperti MCB, MCCB, dan ACB. Kesempatan untuk meningkatkan performa produksinya dalam rangka meningkatkan profit perusahaan dapat dilakukan dengan usaha mengurangi biaya, meningkatkan kualitas dan ketepatan waktu pengiriman ke konsumen. Untuk mencapai objektif tersebut, maka perusahaan wajib mengetahui aktivitas mana yang memungkinkan peningkatan value-added pada produk (produk/jasa), pengurngan akyivitas yang tidak perlu (waste), dan pemangkasan waktu produksi. Oleh sebab itu, dibutuhkan suatu pendekatan Lean Manufacturing. Tujuan dari penelitian ini adalah PT Schneider Electric Indonesia memperkirakan kenaikan rasio value added terhadap waste apabila diterapkan lean strategy. Pemahaman mengenai kondisi perusahaan dijelaskan secara umum melalui pemetaan Big Picture Mapping, Seven Waste Tool, yang nantinya juga akan dijelaskan alur kerja menggunakan Value Stream Analysis Tool. Saran perbaikan akan dilakukan menggunakan FMEA (Failure Mode Effectand and Analysis) untuk mengurangi waste pada proses produksi Refrigerator. Berdasarkan data yang diperoleh, ada tiga waste terbesar yang mengurangi prdouktivitas yaitu transportasi 18%, waiting process (16,5%), dan inventory (15,3%). Ketika nilai rata-rata waste dikalikan dengan factor of mapping, maka akan didapatkan detil mengenai dominant Mapping Tools Process Activity Mapping (31.2%), Supply Chain Response Matrix (21.0%), Production Variety Funnel (18, 2%), Quality Filter Mapping (5.6%), Demand Amplification Mapping (3.7%), Decision Point Analysis (11.5%) dan Physical Structure (3.7%). Setelah dibuat pemetaan future state, maka perhitungan value added activity 46%, Non Value Added tapi merupakan aktivitas yang dibutuhkan Necessary adalah 49%, Non Value Added adalah 5% dan Value Added to waste Ratio adalah 75%.
Kata Kunci: Lean Manufacturing, Seven Waste, Value Stream Analysis Tool, FMEA
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