ANALISIS WASTE DAN PERANCANGAN PERBAIKAN PROSES PRODUKSI BARECORE MENGGUNAKAN PENDEKATAN LEAN MANUFACTURING DENGAN INTEGRASI VALUE STREAM MAPPING

Ahmad Latif Aulia Rahman, NIM.: 22106060072 (2026) ANALISIS WASTE DAN PERANCANGAN PERBAIKAN PROSES PRODUKSI BARECORE MENGGUNAKAN PENDEKATAN LEAN MANUFACTURING DENGAN INTEGRASI VALUE STREAM MAPPING. Skripsi thesis, UIN SUNAN KALIJAGA YOGYAKARTA.

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Abstract

Manufacturing industry competition requires companies to improve production efficiency by minimizing non-value-added activities (waste). PT. Duta Albasy, as a wood processing company, still faces several wastes in its barecore production process, such as defects, waiting time, and work in process (WIP) accumulation, which contribute to high production lead time. This study aims to identify the types of waste, determine the priority level of production risks, and propose improvement recommendations using the Lean Manufacturing approach through Value Stream Mapping (VSM) and Failure Mode and Effect Analysis (FMEA). The research was conducted on the barecore production line with dimensions of 13 mm × 1220 mm × 2440 mm at PT. Duta Albasy during January 2026. The VSM method was used to map the current state map and future state map in order to identify value-added and non-value-added activities. Furthermore, the FMEA method was applied to determine improvement priorities based on the Risk Priority Number (RPN). The results showed that the main wastes identified were product defects in the form of core trap and cutter mark, waiting time before the GangRip process of 80 minutes and after the sorting process of 18 minutes, as well as inventory/WIP accumulation before the GangRip process. The FMEA results indicated that the highest RPN values were found in core trap defects and WIP before GangRip, both scoring 50, followed by cutter mark with 42 and waiting time with 32. The proposed improvements include increasing the GangRip machine capacity from 1 unit to 2 units, implementing a FIFO system, applying preventive maintenance on GangRip and Sawing machines, and improving sorting operator accuracy. The implementation of these improvements reduced the production lead time from 373.71 minutes to 318.74 minutes and improved the flow of the barecore production process.

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