PENDEKATAN LEAN MANUFACTURING UNTUK MEMINIMASI WASTE DAN MENINGKATKAN PRODUKTIVITAS PADA PROSES PRODUKSI FINGER JOINT LAMINATED BOARD (STUDI KASUS: CV. GENTONG MAKMUR)

Muhammad Ya’lu Mubarok, NIM.: 21106060051 (2025) PENDEKATAN LEAN MANUFACTURING UNTUK MEMINIMASI WASTE DAN MENINGKATKAN PRODUKTIVITAS PADA PROSES PRODUKSI FINGER JOINT LAMINATED BOARD (STUDI KASUS: CV. GENTONG MAKMUR). Skripsi thesis, UIN SUNAN KALIJAGA YOGYAKARTA.

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Abstract

In the context of global competition, improving productivity is crucial and can be achieved by eliminating or reducing non-value-added activities. CV. Gentong Makmur faces similar challenges in its finger joint laminated board production process, where several forms of waste were identified, resulting in a low production capacity of only 57.5 units per day and frequent delivery delays. This study adopts a lean manufacturing approach by employing value stream mapping (VSM) to analyze value flow, process activity mapping (PAM), and FlexSim simulation to evaluate the effectiveness of improvement strategies. Root causes were identified using the 5 Whys method, and solutions were formulated through the 5W1H approach. The identified types of waste include waiting, transportation, over processing, excess inventory, and motion. Recommended improvements include the addition of one sawper machine and one lamination machine, the use of visual indicators (flags), an additional hand lift, the implementation of scheduled machine maintenance, factory layout optimization, replacing wooden blocks with pallets, applying 5S principles, and developing Standard Operating Procedures (SOP). As a result, the daily production potential increased to 167 units, lead time was reduced by 5% to 11,278.60 seconds, and the number of process activities was reduced from 14. Value-added (VA) time reached 9,518.90 seconds (a4% reduction), non-value-added (NVA) time decreased by 28% to 784.35 seconds, while necessary non-value-added (NNVA) time remained constant.

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