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PENERAPAN KONSEP LEAN MANUFACTURING
UNTUK MEREDUKSI WASTE
PADA PRODUKSI RAKET MERK SANYO
(Perusahaan Raket Abadi Malang)
Skripsi
Diajukan Kepada Universitas Muhammadiyah Malang
Untuk Memenuhi Salah Satu Persyaratan Akademik
Dalam Menyelesaikan Program Sarjana Teknik
Disusun Oleh :
FAIZAL AKHBAR DHARMAWAN
201210140311097
JURUSAN TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH MALANG
(2017)
LEMBAR PENGESAHAN SKRIPSI
PENERAPAN KONSEP LEAN MANUFACTURING
UNTUK MEREDUKSI WASTE
PADA PRODUKSI RAKET MERK SANYO
(Perusahaan Raket Abadi Malang)
Disusun Oleh :
Faizal Akhbar Dharmawan
201210140311097
Menyetujui dan Mengesahkan :
Dosen Pembimbing I
Ir. M. Lukman, M.T.
Mengetahui,
Ketua Jurusan Teknik Industri
Ilyas Mas’udin, M.Log,Scm, Ph.D
Malang, 12 September 2017
Dosen Pembimbing II
Dana Masrsetiya U., S.T., M.T.
KATA PENGANTAR
Segala puji dan syukur kehadirat Allah SWT. Semoga sholawat dan salam
selalu tercurahkan bagi junjungan Nabi besar kita Muhammad SAW beserta
keluarga, sahabat-sahabat beliau dan orang-orang yang mengikutinya dengan
kebaikan hingga akhir jaman.
Alhamdulillahi robbil ‘alamin atas segala rohmat, hidayah, dan karunia
yang telah dilimpahkan-Nya hingga akhirnya penulis dapat menyelesaikan tugas
akhir dengan judul “PENERAPAN KONSEP LEAN MANUFACTURING
UNTUK MEREDUKSI WASTE PADA PRODUKSI RAKET MERK
SANYO”. Penulisan tugas akhir ini dimaksudkan untuk memenuhi tugas sebagai
persyaratan kelulusan dalam menyelesaikan pendidikan Program Sarjana S1
jurusan Teknik Industri. Dalam penulisan tugas akhir ini, penulis telah banyak
mendapatkan bantuan dari berbagai pihak dan semoga yang telah kita lakukan dapat
bermanfaat. Untuk itu tidak lupa penulis ingin mengucapkan terima kasih kepada:
1. Kedua orang tua penulis, Bapak Tamjis dan Ibu Siswo Utami tercinta yang
selalu memberikan doa dan kasih sayang serta dukungan moril, spiritual dan
materiil.
2. Bapak Ilyas Mas’udin, M.Log.SCM, PhD, selaku Ketua Jurusan Teknik
Industri Universitas Muhammadiyah Malang.
3. Ibu Annisa Kessy G, S.T, M.T, selaku Dosen Wali kelas C angkatan 2012
Teknik Industri Universitas Muhammadiyah Malang.
4. Bapak Ir. M. Lukman., M.T, selaku dosen Pembimbing I.
5. Bapak Dana Marsetiya U, S.T, M.T, selaku Pembimbing II.
6. Seluruh dosen dan karyawan jurusan Teknik Industri yang telah
mengajarkan ilmunya.
7. Ibu Lilik, selaku wakil pimpinan Perusahaan raket Abadi dan seluruh
karyawan yang telah memberikan ijin kepada penulis untuk pengambilan
data selama penelitian.
8. Semua keluarga penulis, Mas Wawan, Mbak Kiki, Mbak Yuni, Mas Amin,
Habi, Hayu, Tristan, Pakdhe Agus, Budhe Kunthi, Mas Reza, dan semua
keluarga lain yang tidak dapat ditulis satu persatu terimakasih atas doanya.
9. Teman-teman PPIC ’12, khususnya Aan, Miftah, Erwin, Bay, Farid, Yaqin,
Cicik, Olip, Ocik terimakasih telah menjadikan hari-hari penulis lebih
berwarna ditengah-tengah penulisan tugas akhir ini.
10. Teman-teman asisten laboratorium, terimakasih telah memberikan
dukungan yang sangat berarti bagi penulis.
11. Kawan-kawan organisasi baik HMTI (Himpunan Mahasiswa Teknik
Industri) periode 2013-2014 maupun SWAYANAKA (Mahasiswa
Penyayang Anak-Anak) Malang yang kadangkala meberikan keceriaan
yang penulis butuhkan disaat mengalami kejenuhan dalam penyususnan
tugas akhir ini.
12. Teman-teman LeX (Learning Express) baik dari UMM yakni Adit, Adjar,
Anggoro, Bayu, Ambika, Nina, Tania, Ano, Mei, Sam, maupun dari
Singapore Polytechnic antara lain Mrs. Rubaina, Ze Yu, Shyan Jie, Azeem,
Ben, Chu Wen, Freda, Adonica, Naomi.
13. Serta semua pihak yang tidak dapat penulis sebutkan satu persatu.
Akhir kata penulis berharap semoga tugas akhir ini dapat memberikan
manfaat bagi kita semua, khususnya mahasiswa jurusan Teknik Industri Universitas
Muhammadiyah Malang agar dapat menambah wawasan dalam mempelajari
masalah-masalah yang berkaitan dengan lean manufacturing. Dalam segala hal
tentunya tidak ada yang sempurna dan pasti masih terdapat kekurangan, maka dari
itu penulis siap menerima kritik maupun saran yang bersifat membangun untuk
kesempurnaan penyusunan tugas akhir ini.
Malang, 10 September 2017
Penulis,
Faizal Akhbar Dharmawan
201210140311097
DAFTAR ISI
Halaman Judul ............................................................................................................
Lembar Pengesahan Skripsi ......................................................................................
Lembar Bimbingan Skripsi .......................................................................................
Berita Acara Ujian......................................................................................................
Surat Pernyataan Keaslian..........................................................................................
Surat Keterangan Pengambilan Data dari Perusahaan ...............................................
Kata Pengantar ...........................................................................................................
Abstrak .................................................................................................................... i
Abstract .................................................................................................................. ii
Daftar Isi ................................................................................................................ iii
Daftar Tabel .......................................................................................................... ix
Daftar Gambar ....................................................................................................... xi
Daftar Lampiran .................................................................................................... xii
BAB I PENDAHULUAN
1.1 Latar Belakang Penelitian ................................................................................ 1
1.2 Rumusan Masalah Penelitian ........................................................................... 3
1.3 Tujuan Penelitian .............................................................................................. 3
1.4 Manfaat Penelitian ............................................................................................ 3
1.5 Batasan Masalah dan Asumsi ........................................................................... 4
BAB II LANDASAN TEORI
2.1 Lean Manufacturing Concept ........................................................................... 5
2.1.1 Definisi Lean ............................................................................................... 5
2.1.2 Prinsip Dasar Lean ....................................................................................... 6
2.2 Waste (Pemborosan) dalam Lean Manufacturing .............................................. 7
2.2.1 Perbedaan Tiga Jenis Kegiatan .................................................................... 7
2.2.2 Jenis-jenis Waste .......................................................................................... 8
2.2.3 Hubungan antar Waste ............................................................................... 10
2.3 Big Picture Mapping ........................................................................................ 12
2.3.1 Bagian-bagian dari Big Picture Mapping .................................................. 14
2.3.2 Simbol-simbol Big Picture Mapping ......................................................... 16
2.2.3 Hubungan antar Waste ............................................................................... 10
2.4 Analytical Networking Process ........................................................................ 17
2.4.1 Struktur Analytical Networking Process ................................................... 19
2.4.2 Konsep Dasar Analytical Networking Process .......................................... 23
2.4.3 Tahap Pengerjaan Analytical Networking Process .................................... 23
2.4.4 Kekurangan dan Kelebihan Analytical Networking Process ..................... 27
2.5 Value Stream Analysis Tools ............................................................................ 28
BAB III METODOLOGI PENELITIAN
3.1 Metodologi Penelitian ...................................................................................... 32
3.2 Deskripsi Metodologi Penelitian ...................................................................... 32
3.2.1 Tahap Pengidentifikasian Masalah ............................................................ 32
3.2.1.1 Penentuan Topik .................................................................................. 32
3.2.1.2 Studi Literatur ...................................................................................... 32
3.2.1.3 Studi Lapangan .................................................................................... 34
3.2.1.4 Identifikasi dan Rumusan Masalah ..................................................... 34
3.2.2 Tahap Pengambilan Data ........................................................................... 34
3.2.3 Tahap Pengolahan Masalah ....................................................................... 34
3.2.3.1 Pembuatan Big Picture Mapping ........................................................ 35
3.2.3.2 Pembobotan Waste Berdasarkan Analytical Networking Process ...... 35
3.2.3.2 1. Kontruksi Model ........................................................................... 35
3.2.3.2 2. Matriks Perbandingan Berpasangan ............................................. 36
3.2.3.2 3. Rasio Konsistensi ......................................................................... 38
3.2.3.2 4. Supermatriks ................................................................................. 38
3.2.3.3 Pemilihan Waste yang Dominan ......................................................... 39
3.2.3.4 Pemilihan Detailed Mapping Tools dengan VALSAT ....................... 39
3.2.4 Tahap Analisa ............................................................................................ 40
3.2.4.1 Analisa Penyebab Waste yang Dominan Berdasarkan Fishbone ........ 40
3.2.4.2 Usulan Perbaikan Berdasarkan Diagram Fishbone ............................. 40
3.2.5 Tahap Kesimpulan dan Saran .................................................................... 40
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA
4.1 Tinjauan Perusahaan ........................................................................................ 41
4.1.1 Profil Perusahaan ....................................................................................... 41
4.1.2 Lokasi Perusahaan ..................................................................................... 41
4.1.3 Struktur Organisasi .................................................................................... 42
4.1.4 Jam Kerja Karyawan .................................................................................. 44
4.1.4 Proses Produksi Raket Merk Sanyo ........................................................... 45
4.2 Pengumpulan dan Pengolagan Data ................................................................. 47
4.2.1 Pembuatan Big Picture Mapping ............................................................... 47
4.2.1.1 Aliran Informasi .................................................................................. 47
4.2.1.2 Aliran Fisik .......................................................................................... 48
4.2.1.2.1 Aliran Fisik Raket Merk Sanyo Keseluruhan ............................... 48
4.2.1.2.2 Aliran Fisik Part Head .................................................................. 50
4.2.1.2.3 Aliran Fisik Part Shaft .................................................................. 51
4.2.1.2.4 Aliran Fisik Part Handle .............................................................. 51
4.2.2 Pembobotan Wastes Berdasarkan Analytical Networking Process ............ 52
4.2.2.1 Pembentukan Jaringan antar Waste ..................................................... 52
4.2.2.2 Pengolahan Data Kuesioner Dampak Hubungan antar Waste ............ 54
4.2.2.3 Matriks Perbandingan Berpasangan .................................................... 56
4.2.2.4 Rasio Konsistensi ................................................................................ 57
4.2.2.5 Supermatriks ........................................................................................ 58
4.2.2.6 Bobot Masing-masing Waste ............................................................... 59
4.2.3 Pemilihan Waste yang Dominan ................................................................ 60
4.2.4 Pemilihan Detailed Mapping Tools dengan VALSAT .............................. 61
4.2.4.1 SCRM (Supply Chain Response Matrix) ............................................. 62
4.2.4.2 DAM (Demand Amplification Mapping) ............................................ 64
BAB V ANALISA PEMBAHASAN
5.1 Identifikasi Waste yang Dominan .................................................................... 67
5.1.1 Analisa Big Picture Mapping .................................................................... 67
5.1.2 Analisa Pembobotan Waste Berdasaran ANP ........................................... 68
5.2 Penentuan Mapping Tools Berdasarkan VALSAT .......................................... 71
5.2.1 Analisa VALSAT (Value Stream Analysis Tool) ...................................... 71
5.2.2 Analisa Supply Chain Response Matrix .................................................... 72
5.2.3 Analisa Demand Amplification Mapping .................................................. 73
5.3 Analisa Penyebab Waste yang Dominan Berdasarkan Fishbone ..................... 74
5.3.1 Diagram Fishbone untuk Waste Overproduction ...................................... 75
5.3.2 Diagram Fishbone untuk Waste Inventory ................................................ 77
5.4 Usulan Perbaikan ............................................................................................. 79
5.4.1 Usulan Perbaikan untuk Waste Overproduction ........................................ 79
5.4.2 Usulan Perbaikan untuk Waste Inventory .................................................. 83
5.5 Usulan Perbaikan Berdasarkan Aplikasi Rencan Produksi .............................. 85
5.5.1 Supply Chain Response Matrix Setelah Perbaikan .................................... 87
5.5.2 Demand Amplification Mapping Setelah Perbaikan .................................. 89
5.5.3 Perbandingan Kelebihan Produksi Sebelum dan Sesudah ......................... 90
BAB VI PENUTUP
6.1 Kesimpulan .............................................................................................. 91
6.2 Saran ....................................................................................................... 92
DAFTAR PUSTAKA ........................................................................................... 93
LAMPIRAN .......................................................................................................... 97
DAFTAR TABEL
Table 2.1 Hubungan antar Tujuh Waste ................................................................. 10
Table 2.2 Simbol-simbol Big Picture Mapping ..................................................... 16
Table 2.3 Skala Numerik Analytical Networking Process ..................................... 24
Table 2.4 Indeks Konsistesi Acak .......................................................................... 26
Table 2.5 The Seven Stream Mapping Tools .......................................................... 28
Table 3.1 Skala Numerik Analytical Networking Process ..................................... 36
Table 3.2 The Seven Stream Mapping Tools .......................................................... 39
Table 4.1 Hubungan antar Tujuh Wastes ............................................................... 52
Table 4.2 Penjabaran Nilai Hubungan Antar Waste .............................................. 55
Table 4.3 Skala Numerik Analytical Networking Process ..................................... 56
Table 4.4 Matriks Perbandingan Berpasangan....................................................... 56
Table 4.5 Rasio Konsistensi ................................................................................... 57
Table 4.6 Unweighted Supermatriks ...................................................................... 58
Table 4.7 Weighted Supermatriks .......................................................................... 58
Table 4.8 Limit Matriks .......................................................................................... 59
Table 4.9 Bobot Masing-masing Waste ................................................................. 59
Tabel 4.10 Data Pemesanan Raket Merk Sanyo Pada tahun 2016 ........................ 60
Tabel 4.11 Hasil PembobotanVALSAT ................................................................ 61
Tabel 4.12 Hasil Perhitungan Day’s Physical Stock .............................................. 63
Tabel 4.13 Data Demand Amplification Mapping ................................................. 65
Table 5.1 Hubungan Saling Mempengaruhi Antar Waste ..................................... 69
Table 5.2 Data Jenis Cacat ..................................................................................... 70
Table 5.3 Hasil Pembobotan VALSAT ................................................................. 71
Table 5.4 Perbandingan pada SCRM Antara Ketiga Area ..................................... 72
Table 5.5 Penilaian Penyebab Utama Waste Overproduction ............................... 77
Table 5.6 Penilaian Penyebab Utama Waste Inventory ......................................... 79
Table 5.7 Peramalan Permintaan Raket Merk Sanyo Januari – Maret 2016 ......... 83
Table 5.8 Peramalan Permintaan Raket Merk Sanyo April – Mei 2016 ................ 83
Table 5.9 Safety Stock Bulan Januari – Mei 2016 .................................................. 85
Table 5.10 Rencana Produksi Raket Merk Sanyo 2016 ......................................... 86
Table 5.11 Hasil Perhitungan Day’s Physical Stock Setelah Perbaikan ................ 87
Table 5.12 Data Demand Amplification Mapping Setelah Perbaikan.................... 87
DAFTAR GAMBAR
Gambar 2.1 Hubungan Tujuh Waste ...................................................................... 10
Gambar 2.2 Big Picture Map ................................................................................. 13
Gambar 2.3 Perbedaan Struktur Hirarki Linier dengan Jaringan Umpan Balik .... 19
Gambar 2.4 Jenis Komponen dalam Jaringan ........................................................ 20
Gambar 2.5 Struktur Hirarki Linier ....................................................................... 21
Gambar 2.6 Struktur Holarki.................................................................................. 21
Gambar 2.7 Struktur Benefit Costs Ratio ............................................................... 22
Gambar 2.7 Struktur Jaringan Umum .................................................................... 22
Gambar 2.6 Struktur Holarki.................................................................................. 21
Gambar 3.1 Diagram Alir Metodologi Penelitian .................................................. 33
Gambar 3.2 Langka-langkah Analytical Networking Process ............................... 35
Gambar 3.3 Hubungan Tujuh Wastes .................................................................... 36
Gambar 4.1 Struktur Organisasi Perusahaan ......................................................... 42
Gambar 4.2 Operation Prcoess Chart Raket Merk Sanyo .................................... 45
Gambar 4.3 Hubungan antar Tujuh Wastes ........................................................... 52
Gambar 4.4 Supply Chain Response Matrix .......................................................... 63
Gambar 4.5 Demand Amplification Mapping ........................................................ 65
Gambar 5.1 Bobot Masing-Masing Waste (Pemborosan) ..................................... 68
Gambar 5.2 Perbandingan DAM Recana Produksi dengan Output Produksi ........ 73
Gambar 5.3 Perbandingan DAM Produk Dipesan dengan Produk Terkirim......... 74
Gambar 5.4 Diagram Fishbone untuk Waste Overproduction .............................. 75
Gambar 5.5 Diagram Fishbone untuk Waste Inventory ......................................... 77
Gambar 5.6 Plotting Data Permintaan Raket Merk Sanyo Tahun 2015 ................ 80
Gambar 5.7 Usulan Perbaikan Aplikasi Perencanaan Produksi............................. 85
Gambar 5.8 Supply Chain Response Matrix Setelah Perbaikan ............................ 88
Gambar 5.9 Demand Amplification Mapping Setalah Perbaikan .......................... 89
Gambar 5.10 Grafik Persentase Perdandingan Sisa Persediaan di Akhir Bulan .... 90
DAFTAR LAMPIRAN
Lampiran 1. Dokumentasi Proses Produksi ........................................................... 97
Lampiran 2. Big Picture Mapping ....................................................................... 104
Lampiran 3. Hasil Brainstorming Hubungan antar Wate..................................... 109
Lampiran 4. Kuesioner Dampa Hubungan antar Waste ....................................... 114
Lampiran 5. Langkah-langkah Menggunakan Software Super Decision............. 120
Lampiran 6. Rekap Data Jumlah Penggunaan Material ....................................... 126
Lampiran 7. Hasil Brainstorming untuk Pembuatan Fishbone ........................... 133
Lampiran 8. Perhitungan Manual Peramalan Permintaan.................................... 137
Lampiran 9. Pembuatan Aplikasi Rencana Produksi Menggunakan VB 6.0 ...... 144
Lampiran 10. Langkah-langkah Menggunakan Aplikasi ..................................... 153
Lampiran 11. Rekap Data Jumlah Penggunaan Material Setelah Perbaikan ....... 155
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