Implementasi Lean Manufacturing dalam Meningkatkan Daya Saing pada Proses Pengemasan Minyak Goreng dengan Metode Value Stream Mapping

Abstract

PT. X is one of the companies which operates in processing palm oil located in the North Sumatra. In doing the production of cooking oil packages of one liter pillow packs, the company is designed with production capacity of 20 pack/minute. In the period of January-August, 2023, it was found that the utility of the machines only reach 77% which caused the production output to be not maximal so that the production cost was high due to defected product such as the leaking containers of 0.2% (January-August, 2023) so that the production was not qualified enough and the time of production cycle time became longer. The attempt to improve or to decrease the waste in the production line was by doing lean manufacturing, using value stream mapping. Today, efficiency and effectiveness of the process of production in the business world are by maximizing profit by driving down production costs in order to achieve the expected target. The research of research showed that wasting activities such as unnecessary motion, waiting and defects which cause longer production cycle time with the activity category weights was 44% of value adding activity, 32% of necessary non- value adding activity, and 24% of non-value adding activity. From the results of processing the data, it was found that the time needed for producing one box of 20 packs was 1,396 seconds. By eliminating the waste, the cycle time would be reduced to 23% so that utility increased to 96% and production cost decreased to IDR. 61/pack.