USULAN PENGURANGAN WASTE PADA PROSES

PRODUKSI DENGAN MENGGUNAKAN WASTE

ASSESMENT MODEL (WAM) DAN VALSAT

(Studi Kasus; PT. Magnum Attack Indonesia)

Skripsi

Diajukan Kepada Universitas Muhammadiyah Malang

Untuk Memenuhi Salah Satu Persyaratan Akademik

Dalam Menyelesaikan Program Sarjana Teknik

Disusun oleh :

RICCA ANDHINI OCTARIA

201510140311048

JURUSAN TEKNIK INDUSTRI

FAKULTAS TEKNIK

UNIVERSITAS MUHAMMADIYAH MALANG

TAHUN 2019

i

KATA PENGANTAR

Puji syukur kehadirat Allah SWT atas segala rahmat, taufik, hidayah, serta

inayah-Nya sehingga penulis dapat menyelesaikan skripsi yang berjudul

“USULAN PENGURANGAN WASTE PADA PROSES PRODUKSI

DENGAN MENGGUNAKAN WASTE ASSESMENT MODEL (WAM) DAN

VALSAT”.Shalawat dan salam semoga tetap tercurahkan kepada teladan kita Nabi

Muhammad SAW, Sang Pelopor Ilmu Pengetahuan untuk membaca tanda-tanda

kekuasaan-Nya.

Penulis menyadari bahwa dalam penelitian sampai penyusunan skripsi ini

tidak akan terwuud tanpa adanya bantuan, bimbingan dan dukungan dari berbagai

pihak. Oleh karena itu, pada kesempatan ini penulis tak lupa mengucapkan terima

kasih banyak kepada :

1. Allah S.W.T yang telah memberikan rahmat dan hidayah sehingga atas

kuasanya penulisan skripsi ini dapat diselesaikan.

2. Bapak Ilyas Masudin M.log.,S.cm.,Ph.D selaku Ketua Jurusan Teknik

Industri Universitas Muhammadiyah Malang dan dosen pembimbing I yang

telah membimbing penulis dengan sabar dan memberikan ilmu baru.

3. Ibu Shanty Kusuma Dewi, ST., MT selaku dosen pembimbing II yang juga

banyak memberikan banyak ilmu dalam pengerjaan skripsi penulis hingga

penulis merasa terbantu hingga tahap penyelesaian..

4. Ibu Ikhlasul Amallynda, ST., MT selaku koordinator skripsi yang telah

membantu lancarnya proses skripsi setahap demi setahap.

5. Ibu Annisa Kesy Garside, ST., MT. selaku dosen penguji I sempro,

terimakasi telah memberikan ilmunya dan dukungannya untuk penulis,

sehingga penulis dapat segera menyelesaikan revisi.

6. Bapak Dana Marsetya Utama, S.T., MT selaku dosen penguji I sempro,

terimakasi telah memberikan ilmunya dan dukungannya untuk penulis,

sehingga penulis dapat segera menyelesaikan revisi.

ii

7. Bapak Ir. H. M. Kholik, M.T. selaku dosen penguji I sidang, terimakasi telah

memberikan ilmunya dan dukungannya untuk penulis, sehingga penulis

dapat segera menyelesaikan revisi.

8. Ibu Dian Palupi Restuputri, S.T., MT. selaku dosen penguji II sidang,

terimakasi telah memberikan ilmunya dan dukungannya untuk penulis,

sehingga penulis dapat segera menyelesaikan revisi.

9. Teristimewa untuk Mama , Papa dan Kakak yang selalu memberikan

semangat, dukungan, nasehat, materi, motivasi dan doa yang tiada hentinya

yang membantu penyelesaian penulisan skripsi ini.

10. Bapak Eka selaku Pimpinan di PT. Magnum Attack yang sudah memberikan

kesempatan untuk penelitian di perusahaannya.

11. Seluruh staff dan jajaran dosen Teknik Industri Universitas Muhammadiyah

Malang.

12. Teman-teman Teknik Industri A 2015, terimakasih sudah menjadi teman

dan keluarga dari awal hingga akhir.

13. Teman-teman seperbimbingan yang sudah mau untuk menemani dan

memberikan informasi agar skripsi penulis dapat terselesaikan.

Penulis menyadari bahwa laporan ini masih jauh dari kesempurnaan, penulis

berharap adanya kritikan dan masukan dari pembaca untuk kesempurnaan laporan

ini. Semoga laporan ini bermanfaat bagi semua yang membaca.

Malang, 18 November 2019

Penulis,

Ricca Andhini Octaria

201510140311048

Daftar Isi

Kata Pengantar .................................................................................................................... i

Abstrak ............................................................................................................................. iii

Daftar Isi ............................................................................................................................ v

Daftar Tabel ..................................................................................................................... vii

Daftar Gambar ................................................................................................................viii

Daftar Lampiran ................................................................................................................ ix

BAB I PENDAHULUAN .................................................................................................. 1

1.1 Latar Belakang ................................................................................................... 1

1.2 Rumusan Masalah .............................................................................................. 3

1.3 Tujuan Penelitian................................................................................................ 3

1.5 Batasan Masalah ................................................................................................. 4

BAB II LANDASAN TEORI ............................................................................................ 5

2.1 Lean Manufacturing ............................................................................................... 5

2.1.1 Definisi Lean Manufacturing ......................................................................... 5

2.1.2 Konsep Lean Manufacturing .......................................................................... 6

2.2 Waste Assesment Model ......................................................................................... 8

2.2.1 Seven Waste Relationship ............................................................................... 8

2.2.2 Waste Relationship Matrix (WRM) ............................................................... 13

2.2.3 Waste Assesment Questionnaire (WAQ) ....................................................... 14

2.3 Value Stream Analysis Tools (VALSAT) ............................................................... 16

2.4 Value Stream Mapping (VSM) .............................................................................. 19

2.5 Konsep Time Study ............................................................................................... 24

2.6 Konsep Fishbone Diagram .................................................................................. 24

2.7 Failure Mode and Effect Analysis ........................................................................ 24

2.8 Kajian Induktif ..................................................................................................... 28

BAB III METODOLOGI PENELITIAN............................................................... 31

3.1 Objek Penelitian .......................................................................................... 31

3.2 Metode Pengumpulan Data ......................................................................... 31

3.3 Prosedur Penelitian...................................................................................... 32

3.3.1 Tahap Pendahuluan .............................................................................. 33

3.3.2 Tahap Pengumpulan dan Pengolahan Data ......................................... 33

3.3.3 Tahap Analisa dan Pembahasan .......................................................... 36

3.3.4 Kesimpulan dan Saran ......................................................................... 37

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA ............................................ 38

4.1 Deskripsi Perusahaan ....................................................................................... 38

4.2 Proses Produksi ................................................................................................ 40

4.3 Data Produksi ................................................................................................... 43

4.4 Tata Letak Produksi ......................................................................................... 43

4.5 Waste Dominan Perusahaan ............................................................................. 45

4.6 Value Stream Mapping ..................................................................................... 47

4.6.1 Aliran Informasi ....................................................................................... 48

4.6.2 Aliran Fisik ............................................................................................... 49

4.7 Waste Assesment Model .................................................................................. 49

4.7.1 Seven Waste Relationship Matrix ............................................................ .50

4.7.2 Waste Assesment Questionnaire ............................................................... 53

4.8 VALSAT (Value Stream Analysis Tools) ........................................................ 55

4.8.1 Process Activity Mapping ........................................................................ 56

4.8.2 Supply Chain Response Matrix ................................................................ 67

4.8.3 Quality Filter Mapping (QFM) ................................................................. 69

4.8.4 Demand Amplification Mapping (DAM) ................................................. 70

4.9 Hasil Identifkasi Pemborosan ........................................................................... 72

4.10 Eliminasi Pemborosan ...................................................................................... 73

BAB V ANALISA PEMBAHASAN ............................................................................... 78

5.1 Analisa Value Stream Mapping ........................................................................ 78

5.2 Analisa Waste Assesment Model ...................................................................... 78

5.3 Analisa Process Activity Mapping Tool ........................................................... 81

5.4 Supply Chain Response Matrix ........................................................................ 82

5.5 Analisa Demand Amplification Mapping dan Quality Filter Mapping ............. 83

5.6 Failure Mode Effect Analysis (FMEA) ............................................................ 83

5.7 Usulan Perbaikan.............................................................................................. 84

5.7.1 Pembuatan tag rack .................................................................................. 84

5.7.2 Pengelompokkan Material dengan Klasifikasi ABC .................................... 88

BAB VI PENUTUP ......................................................................................................... 92

6.1 Kesimpulan ...................................................................................................... 92

6.2 Saran ................................................................................................................ 93

Daftar Gambar

Gambar 2.1 Waste Relation ................................................................................................ 8

Gambar 2.2 Current Value Stream Mapping .................................................................... 23

Gambar 4.1 Struktur Organisasi PT. Magnum Attack Indonesia ..................................... 39

Gambar 4.2 Layout 1 Perusahaan ..................................................................................... 43

Gambar 4.3 Layout 2 Perusahaan ..................................................................................... 44

Gambar 4.4 Value Stream Mapping ................................................................................. 46

Gambar 4.5 Diagram Pareto Hasil Waste Assesment Model............................................. 53

Gambar 4.6 Uji Keseragaman Data A1 ............................................................................ 58

Gambar 4.7 Kumulatif Data Pemakaian Bahan Baku ...................................................... 66

Gambar 4.8 Data Pengeluaran Produksi ........................................................................... 66

Gambar 4.9 Data Permintaan Produk ............................................................................... 66

Gambar 4.10 Supply Chain Response Matrix ................................................................... 68

Gambar 4.11 Grafik Reject Rate Pemotongan, Penjahitan dan Packaging ....................... 69

Gambar 4.12 Perbandingan permintaan dan output produksi ........................................... 70

Gambar 4.13 Demand Amplification Mapping ................................................................. 70

Gambar 5.1 Grafik days physical stock kaos .................................................................... 82

Gambar 5.2 Kondisi rak material saat ini ......................................................................... 85

Gambar 5.3 Kondisi penyimpanan sisa kain saat ini ........................................................ 85

Gambar 5.4 Kondisi penyimpanan peralatan saat ini ....................................................... 85

Gambar 5.5 Design label tag rack untuk material ............................................................ 86

Gambar 5.6 Layout Rak Material Saat Ini ........................................................................ 87

Gambar 5.7 Usulan layout baru rak 2 material ................................................................. 89

Gambar 5.8 Usulan layout baru rak 3 material ................................................................. 90

Gambar 5.9 Layout rak usulan ......................................................................................... 91

Daftar Tabel

Tabel 2.1 Hubungan waste overproduction ........................................................................ 9

Tabel 2.2 Hubungan waste inventory ................................................................................. 9

Tabel 2.3 Hubungan waste defects ................................................................................... 10

Tabel 2.4 Hubungan waste motion ................................................................................... 10

Tabel 2.5 Hubungan antar waste transport ...................................................................... 10

Tabel 2.6 Hubungan waste process .................................................................................. 11

Tabel 2.7 Hubungan waste waiting .................................................................................. 11

Tabel 2.8 Pembobotan dari Seven Waste Relationship ..................................................... 12

Tabel 2.9 Waste Relationship Matrix ............................................................................... 13

Tabel 2.10 Konversi Range dari Matriks Hubungan Antar Waste .................................... 13

Tabel 2.11 Matriks 7 VALSAT .......................................................................................... 18

Tabel 2. 12 Lambang VSM .............................................................................................. 20

Tabel 2.13 Tabel Severity ................................................................................................. 26

Tabel 2.14 Occurrence rank............................................................................................. 27

Tabel 2.15 Detection Rank ............................................................................................... 27

Tabel 2.16 Kajian Induktif ............................................................................................... 30

Tabel 4.1 Jobdesc Perusahaan .......................................................................................... 39

Tabel 4.2 Data Permintaan 2018-2019 ............................................................................. 42

Tabel 4.3 Rekapitulasi Seven Waste Relationship ............................................................ 49

Tabel 4.4 Keterkaitan antar Waste ................................................................................... 51

Tabel 4.5 Matriks Keterkaitan antar Waste ...................................................................... 52

Tabel 4.6 Rekapitulasi Hasil Pembobotan Waste Assesment Questionnaire .................... 53

Tabel 4.7 Faktor Pengali VALSAT .................................................................................. 54

Tabel 4.8 Hasil Perhitungan VALSAT ............................................................................ 54

Tabel 4.9 Uji Kecukupan Data ......................................................................................... 55

Tabel 4.10 Process Activity Mapping ............................................................................... 58

Tabel 4.11 Hasil Presentase dan Perhitungan ................................................................... 64

Tabel 4.12 Perhitungan Supply Chain Response Matrix .................................................. 67

Tabel 4.13 Data Reject Kaos ............................................................................................ 68

Tabel 4.14 Daftar Permintaan dan Pengeluaran .............................................................. 69

Tabel 4.15 Pemborosan paling dominan di perusahaan .................................................... 71

Tabel 4.16 Failure Mode Effect Analysis ......................................................................... 72

Tabel 5.1 Klasifikasi ABC Bahan Baku ........................................................................... 88

i

Daftar Lampiran

Lampiran 1 Data Produksi ............................................................................................... 97

Lampiran 2 Data Uji Keseragaman ................................................................................. 98

Lampiran 3 Kuesioner Penelitian ................................................................................... 101

Lampiran 4 Waste Assesment Questionnaire ................................................................. 139

94

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