Optimalisasi Pendekatan Lean Manufacturing Untuk Mengurangi Waste Dan Usulan Perubahan Tata Letak Pada Divisi Oven PT. XYZ. (Optimization of Lean Manufacturing Approach to Reduce Waste and Proposed Layout Changes in the Oven Division of PT. XYZ).

Gunawan, Akilla Alfrets Deanoffa (2024) Optimalisasi Pendekatan Lean Manufacturing Untuk Mengurangi Waste Dan Usulan Perubahan Tata Letak Pada Divisi Oven PT. XYZ. (Optimization of Lean Manufacturing Approach to Reduce Waste and Proposed Layout Changes in the Oven Division of PT. XYZ). Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

Operational efficiency in the production process of the SS-29 oven machine at PT. XYZ was a critical focus to enhance productivity and reduce waste. Lean Manufacturing was implemented using the 5W+1H method to identify types of waste, time study analysis to measure non-value-added activity durations, and systematic layout planning (SLP) to redesign the layout for optimizing material flow. Data collection included process time, material transfer distances, and operator activities, which were then used to develop a current state value stream mapping. The results revealed three dominant types of waste—waiting, transportation, and motion—that significantly contributed to inefficiencies. The initial layout featured a material transfer distance of 461.1 meters, leading to waiting times of up to 1800 seconds per shift. Following the implementation of the new layout, the material transfer distance was reduced to 271.5 meters, approximately 41% shorter. Waiting time decreased by 50%, and production cycle efficiency improved from 158.13 seconds to 123.5 seconds. These changes allowed operators to focus more on value-added activities, enhancing operational efficiency and supporting production targets. The application of Lean Manufacturing methods and the new layout not only reduced time and production costs but also created a more responsive and organized workflow. This approach enabled PT. XYZ to achieve higher efficiency and an overall increase in productivity.

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