Institutional Repository UIN Sunan Kalijaga YogyakartaANALISIS PENINGKATAN EFISIENSI PROSES PRODUKSI ROTI TAWAR DENGAN PENDEKATAN LEAN MANUFACTURING MENGGUNAKAN WASTE ASSESSMENT MODEL (STUDI KASUS: PABRIK ROTI BAKAR ASHARI)NIM.: 22106060051Abdurrahman LabibauthorPabrik Roti Bakar Ashari is a small and medium-sized enterprise (SME) in Yogyakarta producing sliced bread, whose production process still shows indications of waste, such as sudden dough mixer breakdowns, defective (burnt) products that cannot be reworked, the absence of a written standard operating procedure (SOP), and a limited workforce. This study analyzes the current condition and efficiency of the production process, identifies the most dominant waste, examines its root causes, and formulates improvement proposals through a lean manufacturing approach, using Value Stream Mapping (VSM), the Waste Assessment Model (WAM) — comprising the Seven Waste Relationship (SWR), Waste Relationship Matrix (WRM), and Waste Assessment Questionnaire (WAQ) — Value Stream Analysis Tools (VALSAT), Process Cycle Efficiency (PCE), and 5 Whys Analysis. The results show that the current PCE is 59.40%, with defects as the dominant waste (19.77%), followed by unnecessary motion (18.57%), inventory (14.53%), overproduction (14.23%), and excessive transportation (13.93%). Process Activity Mapping (PAM), selected through VALSAT weighting as the most suitable follow-up tool, further revealed that waiting waste contributed 87.64% of total non-value-added (NVA) time, particularly at the cooling stage, the process's critical point (PCE 28.22%). The proposed improvements increased PCE to 67.73%, a rise of 8.33 percentage points, with the cooling stage improving most significantly from 28.22% to 37.68%, bringing every production stage into a lean condition (PCE above 30%).670 Teknik Industri2026-08-19UIN SUNAN KALIJAGA YOGYAKARTA;FAKULTAS SAINS DAN TEKNOLOGIThesis

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