Usulan Perbaikan Aktivitas Non-Value Added pada Proses Produksi Polybag Menggunakan Value Stream Mapping dan FMEA

Abstract

CV. XYZ is a polybag manufacturing company. The company has a production capacity of 40 tons per month. It faces challenges due to defects exceeding the company's quality standards (4%) and waiting time at one of the production stations. The defects consist of hard polybag plastic rolls that cannot be processed further and polybag scraps that need reworking. The waiting time issue involves the accumulation of polybag rolls at the cutting station. The research aims to identify and propose improvements for non-value-added activities on the production floor of CV. XYZ. The methods used in this research are Value Stream Mapping (VSM) and Failure Mode and Effect Analysis (FMEA). Based on observations using value stream mapping, CV. XYZ has 37 activities with a manufacturing lead time of 7.794,71 seconds, consisting of 7.340,94 seconds of value-added activities, 106,00 seconds of necessary non-value-added activities, and 347,77 seconds of non-valueadded activities with a 94,18% process cycle efficiency . Improvements were made to necessary non-value-added activities by changing the work method in elements 9 and 21 from taking one roll at a time to taking 20 rolls at once in a sack and by eliminating non-value-added activity from element 14. The proposed improvements were training and creating Standard Operating Procedures (SOPs) to enable operators to promptly address failures in the blow molding machine and establishing regular maintenance schedules for the cutting machine in the cutting station. After the improvements, CV. XYZ has 36 activities with a reduced manufacturing lead time from 7.794,71 seconds to 7.430,61 seconds, consisting of 7.340,94 seconds of value-added activities, 96,87 seconds of necessary non-valueadded activities, and 0 seconds of non-value-added activities with a 98,58% process cycle efficiency. The process cycle efficiency increased from 94,18% to 98,58%