MEMINIMASI WASTE DENGAN PENDEKATAN LEAN

MANUFACTURING PADA PROSES PRODUKSI PIPA SPIRAL

DI PT. KHI PIPE INDUSTRIES

Rodhotul Janah1, Evi Febianti ST, MT2, Kulsum ST, MT3

Jurusan Teknik Industri, Fakultas Teknik Untirta
Jl. Jend. Sudirman KM 3 Cilegon, Banten 42435
Rodho.janah@yahoo.com1, Evifebianti@yahoo.com2, kulsum.ti@gmail.com3

ABSTRAK

PT. KHI Pipe Industries adalah perusahaan manufaktur yang khusus di bidang
produksi pipa. Pada proses produksi pipa di PT. KHI salah satunya
menggunakan mesin SPM 2000 yang menghasilkan pipa spiral dengan ukuran 53
meter dan kegiatan produksinya lebih banyak dari pada kegiatan produksi pada
mesin lain sering terjadinya hambatan ataupun aktivitas yang tidak memberikan
nilai tambah. Tujuan dari penelitian ini adalah untuk 1. Mengetahui 3 waste
terbesar yang terjadi pada produksi pipa spiral di SPM 2000, 2. Meningkatkan
persentase nilai Proces Cycle Eficiency (PCE) dan Manufacturing Cycle
Effectiveness (MCE) sebelum dan sesudah rekomendasi dan memberikan usulan
perbaikan untuk proses produksi pipa spiral. Metode yang digunakan untuk
mengatasi waste yaitu dengan lean manufacturing yang diantaranya terdapat 7
macam pemborosan yaitu overproduction, transportation waste, waiting, over
processing waste, inventory, motion waste, dan defect product waste. Setelah
dilakukan identifikasi terhadap seven waste, lalu dilakukanlah pemetaan untuk
mengetahui tools yang tepat dengan menggunakan Value Stream Analysis Tools
(VALSAT). Berdasarkan perhitungan waste workshop didapatkan persentase
waste yang terjadi yaitu waiting 20%, over processing 16,19%, transportation
15,24%, defect 14,29%, inventory 12,38%, motion 11,43% dan overproduction
10,48% dengan lead time 445 menit dan nila persentase PCE dan MCE 61%.
Untuk mengurangi lead time yang terjadi perlu dirancang perbaikan dengan
menggunakan tools Process Activity Mapping, Value Stream Mapping dan Root
Cause Analysis untuk melihat akar dari permasalahaan terjadi. Setelah itu
kemudian dibuatlah PCE dan MCE future dengan persentase 73%

Katakunci : Lean Manufacturing, Proces Cycle Efficiency (PCE), Manufacturing

Cycle Effectiveness (MCE), Root Cause Analysis (RCA)
 Minimizing Waste With Lean Manufacturing Approach In Spiral
Pipe Production Process At PT . KHI Pipe Industries

Rodhotul Janah1, Evi Febianti ST, MT2, Kulsum ST, MT3

Department of Industrial Engineering University of Sultan Ageng Tirtayasa
Jl. Jend. Sudirman KM 3 Cilegon, Banten 42435
Rodho.janah@yahoo.com1, Evifebianti@yahoo.com2, kulsum.ti@gmail.com3

ABSTRACT

PT. KHI Pipe Industries is a manufacturing company specialized in the

production pipeline. In the process of pipe production in PT. KHI one of them
using a machine SPM 2000 which produces spiral pipes with a size of 53 meters
and production activities more than on production activities on other machines
frequent occurrence of resistance or activities that do not add value. The purpose
of this study was to 1. Knowing third largest waste that occurs in the production
of spiral pipe in SPM 2000 2. Increase the percentage value Proces Cycle
Efficiency (PCE) and Manufacturing Cycle Effectiveness (MCE) before and after
the recommendations and provide suggestions for process improvement spiral
pipe production. The methods used to cope with lean manufacturing waste,
namely that of which there are seven kinds of waste is overproduction, waste
transportation, waiting, over waste processing, inventory, motion waste, and the
waste product defect. After the identification of the seven waste, and then perform
the mapping to find the right tools to use Value Stream Analysis Tools (VALSAT).
Based on the calculation of the percentage obtained workshop waste waste that
occurs is waiting 20%, processing over 16.19%, 15.24% transportation, defect
14.29%, 12.38% inventory, motion and overproduction 11.43% 10.48% with a
lead time of 445 minutes and tilapia percentage of PCE and MCE 61%. To reduce
the lead time that happens needs to be designed improvements by using the tools
Process Activity Mapping, Value Stream Mapping and Root Cause Analysis to see
the roots of permasalahaan occur. After that then made PCE and MCE future
with a percentage of 73%

Katakunci : Lean Manufacturing, Proces Cycle Efficiency (PCE),

Manufacturing Cycle Effectiveness (MCE),Root Cause Analysis (RCA)