Peningkatan Kapasitas Produksi dengan Metode Lean Manufacturing pada Industri Furnitur

Ades Yulia  Apriani; Humiras Hardi Purba; Erry Rimawan; Singgih Juniawan

doi:10.30656/intech.v10i2.9176

Authors

Ades Yulia Apriani Universitas Mercu Buana
Humiras Hardi Purba Universitas Mercu Buana https://orcid.org/0000-0002-8166-6845
Erry Rimawan Universitas Mercu Buana
Singgih Juniawan Universitas Mercu Buana https://orcid.org/0009-0007-3239-2730

DOI:

https://doi.org/10.30656/intech.v10i2.9176

Keywords:

Lean Manufacturing , Root Cause Analysis, Value Stream Mapping , 5W1H

Abstract

Industri furnitur kayu di Indonesia memiliki peranan penting dalam ekonomi nasional dikarenakan mampu menyerap tenaga kerja dalam jumlah besar. Salah satu perusahaan furniture nasional yang berada di daerah Cikarang memiliki kapasitas produksi 70,03% atau di bawah rata-rata nasional sebesar 74,16%. Penelitian ini bertujuan untuk mengetahui tingkat utilitas produksi saat ini dan strategi dalam meningkatkan tingkat produktivitas beserta implementasi solusi yang dilakukan. Metode yang digunakan dalam penelitian ini adalah Value Stream Mapping (VSM) dalam memvisualisasikan dan menganalisis alur proses produksi furnitur untuk mengetahui potensi penyebab waste atau pemborosan operasional proses produksi serta penerapan pendekatan Root Cause Analysis (RCA) berupa metode 5W1H untuk menghilangkan akar penyebab masalah pada proses produksi furnitur. Hasil penelitian menunjukkan bahwa tingkat utilitas jam kerja produksi sebelum dilakukan perbaikan adalah sebesar 108,67% yang mengindikasikan bahwa fasilitas produksi saat ini sudah dalam posisi maksimal. Penelitian ini berhasil melakukan identifikasi waste terbesar pada Movement, Overproduction dan Waiting. Dengan melakukan perubahan Batch Process baru sebanyak 50 set, pengadaan Mesin CNC Cutting for Leather and Fabric sebanyak empat unit, pengadaan Mesin CNC Cutting for Woodworking sebanyak tiga unit serta penambahan operator sebanyak 43 orang didapatkan perbaikan signifikan pada Lead Time Process menjadi 8,01 hari dari sebelumnya 11,98 hari dan total Cycle Time produksi menjadi 850 menit dari sebelumnya 1.068 menit; kapasitas produksi meningkat dari rata-rata 70,03% menjadi 92,38% atau terjadi kenaikan sebesar 22,35% serta rasio biaya terhadap revenue yang dihasilkan adalah sebesar Rp.674.406.962,80 menghasilkan kontribusi pendapatan sebesar Rp.190.277.737.037,20.

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