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USULAN MEMINIMASI WASTE DENGAN METODE
COST INTEGRATED VALUE STREAM MAPPING
( STUDI KASUS PT. Fajar Putra Plasindo )
Skripsi
Diajukan Kepada Universitas Muhammadiyah Malang
Untuk Memenuhi Salah Satu Persyaratan Akademik
Dalam Menyelesaikan Program Sarjana Teknik
Disusun oleh :
CANDRA PUTRA PAMUNGKAS
201510140311098
JURUSAN TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH MALANG
2019
KATA PENGANTAR
Assalamu’alaikum Wr. Wb.
Alhamdulillah, penulis panjatkan puji syukur kehadirat Allah SWT atas
segala limpahan Rahmat, Berkah, dan Hidayah-Nya serta shalawat dan salam
penulis haturkan kepada Nabi Muhammad SAW yang telah menjadi panutan
sehingga penulis dapat menyelesaikan Skripsi yang berjudul ―Usulan Meminimasi
Waste Dengan Metode Cost Integrated Value Stream Mapping‖. Skripsi ini diajukan
kepada Universitas Muhammadiyah Malang untuk memenuhi salah satu
persyaratan akademik dalam menyelesaikan program Sarjana Teknik.
Selama penyusunan Skripsi ini, penulis telah banyak mendapatkan
bimbingan, arahan, bantuan, motivasi, dan pelatihan mental dari berbagai pihak.
Untuk itu saya selaku penulis mengucapkan terima kasih yang sebesar-besarnya
kepada:
1. Allah atas segala rahmat dan karunia-Nya, sehingga dapat menyelesaikan
tugas akhir atau skripsi ini sampai selesai tepat waktu
2. Ayah dan Ibu, sosok paling berpengaruh dalam penyusunan dan
penyelesaian skripsi ini, ceramah, nasihat, , semua ucapan darinya telah
meningkatkan motivasi hingga dapat menyelesaikan tugas akhir
perkuliahan dengan baik.
3. Bapak Ilyas Mas’udin, Ph.D selaku Ketua Jurusan Teknik Industri
Universitas Muhammadiyah Malang yang telah memberikan ijin kepada
penulis untuk melaksanakan kegiatan penelitian
4. Bapak Ilyas Masudin Ph.D selaku Dosen Pembimbing I yang selalu
bijaksana memberikan bimbingan, nasehat serta waktunya salama
penulisan skripsi ini
5. Bapak Annisa Kesy Garside, S.T., M.T. selaku Dosen Pembimbing II.
Terimakasih atas arahan, dan bimbingan dan nasehat untuk menyelesaikan
penulisan skripsi.
6. Ibu Shanty Kusuma Dewi,. ST. MT selaku dosen penguji 1, penulis
mengucapkan terima kasih sudah memberikan ilmu, dukungan serta
waktunya untuk membimbing penulis, sehingga penulis dapat segera
menyelesaikan revisi sidang tepat waktu.
7. Ibu Dian Palupi ,. ST. MT. selaku dosen penguji 2, penulis mengucapkan
terima kasih sudah memeberikan waktu, dukungan serta waktunya untuk
membimbing penulis, sehingga penulis dapat segera menyelesaikan revisi
sidang tepat waktu.
8. Seluruh Bapak/Ibu Dosen Jurusan Teknik Industri. Terimakasih atas ilmu
yang telah diberikan.
9. Pak Rizal selaku Manajer PPIC di PT. Fajar Putra Plasindo yang telah
membantu proses penelitian hingga selesai.
10. Seluruh keluarga besar Teknik Industri B 2015 yang telah menemani
selama 4 tahun kuliah dan merasakan susah, sedih, dan senang saat masa-
masa kuliah. Semoga yang belum lulus bisa segera lulus dan dilancarkan
dalam segala hal serta tabah dalam menghadapi ujian
11. Teman-teman yang ada di mbah kos dan juga kos barokah, membantu
dalam penyelesaian tugas akhir
Penulis menyadari bahwa dalam penyusunan skripsi ini masih terdapat
kekurangan yang memerlukan penyempurnaan. Untuk itu penulis mengharapkan
kritik dan saran yang bersifat membangun sehingga dapat menambah pengetahuan
penulis dan skripsi ini dapat bermanfaat bagi pembaca pada umumnya serta
perusahaan pada khususnya.
Wassalamu’alaikum Wr. Wb.
DAFTAR ISI
LEMBAR PENGESAHAN SKRIPSI.................................................................................
LEMBAR BIMBINGAN ....................................................................................................
BERITA ACARA UJIAN TUGAS AKHIR .......................................................................
SURAT PERNYATAAN KEASLIAN...............................................................................
SURAT KETERANGAN PERUSAHAAN .......................................................................
KATA PENGANTAR ........................................................................................................
ABSTRACT ......................................................................................................................... i
ABSTRAK ......................................................................................................................... ii
DAFTAR ISI ...................................................................................................................... iii
DAFTAR TABEL .............................................................................................................. vi
DAFTAR GAMBAR ......................................................................................................... vii
DAFTAR LAMPIRAN ...................................................................................................... viii
BAB 1. PENDAHULUAN
1.1 Latar Belakang ........................................................................................................ 1
1.2 Rumusan Masalah ................................................................................................... 2
1.3 Tujuan Penelitian ..................................................................................................... 2
1.4 Manfaat Penelitian ................................................................................................... 3
1.5 Batasan Masalah dan Asumsi .................................................................................. 3
BAB II. LANDASAN TEORI
2.1 Definisi Lean ............................................................................................................ 4
2.2 Pemborosan (waste) ................................................................................................. 6
2.3 Borda Count Method (BCM) .................................................................................. 8
2.4 Value Stream Mapping (VSM) ................................................................................. 9
2.4.1 Langkah-langkah Pembuatan Value Stream Mapping ....................................... 10
2.4.2 Simbol-simbol Value Stream Mapping ............................................................... 11
2.4.3 Kelebihan dan Kekurangan Value Stream Mapping ........................................... 14
2.5 Cost Integrated Value Stream .................................................................................. 14
2.5.1 Analisa Proses .................................................................................................... 17
2.6 Cycle Time, Normal Time, Standart Time ................................................................ 18
2.7 Root Cause Analysis (RCA) ..................................................................................... 19
2.7.1 5 Whys ................................................................................................................. 20
2.7.2 Failure Mode and Effect Analyze (FMEA) ......................................................... 21
BAB III. METODOLOGI PENELITIAN
3.1 Metodologi Penelitian .............................................................................................. 25
3.2 Tahapan Penelitian ................................................................................................... 25
3.2.1 Tahap Pendahuluan ............................................................................................ 27
3.2.2 Tahap Penentuan Topik Penelitian ..................................................................... 27
3.2.3 Tahap Studi Literatur .......................................................................................... 28
3.2.4 Tahap Pengumpulan Data ................................................................................... 28
3.2.5 Tahap Pengolahan Data ...................................................................................... 29
3.2.6 Tahap Analisis dan Pembahasan ......................................................................... 31
3.2.7 Tahap Kesimpulan dan Saran ............................................................................. 31
BAB IV. PENGUMPULAN DAN PENGOLAHAN DATA
4.1 Gambaran Umum Perusahaan .................................................................................. 32
4.1.1 Profil Perusahaan ................................................................................................ 32
4.1.2 Lokasi Perusahaan .............................................................................................. 32
4.1.3 Visi dan Misi Perusahaan .................................................................................... 32
4.1.4 Struktur Organisai Perusahaan ............................................................................ 33
4.1.5 Produk ................................................................................................................. 34
4.1.6 Proses Produksi ................................................................................................... 34
4.2 Pengumpulan Data ................................................................................................... 36
4.2.1 Aliran Informasi .................................................................................................. 36
4.2.2 Aliran Fisik ........................................................................................................ 37
4.2.3 Data Produksi ..................................................................................................... 37
4.2.4 Cycle Time .......................................................................................................... 38
4.2.5 Jumlah Mesin ...................................................................................................... 38
4.2.6 Working Days ...................................................................................................... 39
4.2.7 Biaya Pemakaian Mesin ...................................................................................... 39
4.2.8 Rate Operator ..................................................................................................... 40
4.2.9 Material Cost ...................................................................................................... 40
4.2.10 Jumlah Inventory ............................................................................................... 40
4.2.11 Holding Cost ..................................................................................................... 41
4.2.12 Informasi mengenai pemasok ........................................................................... 41
4.2.13 Bahan Baku ....................................................................................................... 41
4.2.14 Hasil Penyebaran Kusioner ............................................................................... 42
4.3 Pengolahan Data ...................................................................................................... 43
4.3.1 Persiapan Current State Map .............................................................................. 43
4.3.2 Pembuatan Cost Integrated Value Stream Mapping ........................................... 43
4.3.2.1 Total Value Stream Inventory ........................................................................ 43
4.3.2.2 Processing Lead Time ................................................................................... 44
4.3.2.3 Total Value Added Cost ................................................................................. 44
4.3.2.4 Total non Value Added Cost .......................................................................... 46
4.3.2.5 Metric and Baseline Measurement ................................................................ 46
4.3.2.6 Pembobotan Waste ........................................................................................ 49
4.3.3 Identifikasi dengan Root Cause Analysis ............................................................ 51
4.3.4 FMEA waste unnecessary inventory ..................................................................... 53
4.3.5 Usulan Perbaikan .................................................................................................. 56
4.3.6 Future Cost Integrated Value Stream Map ........................................................... 57
BAB V. ANALISA PEMBAHASAN
5.1 Analisis Current Cost Integrated Value Stream Mapping ....................................... 59
5.2 Pemilihan waste yang paling berpengaruh ............................................................ 59
5.3 Analisis penyebab waste dengan Root Cause Analysis ............................................ 60
5.4 Analisis mode kegagalan dan tindakan perbaikan dengan FMEA ........................... 61
5.5 Analisis usulan perbaikan ........................................................................................ 63
5.6 Analisa Future Cost Integrated Value Stream Mapping .......................................... 63
5.7 Analisa perbandingan Current dan Future Cost Integrated Value Stream .............. 64
BAB VI. PENUTUP
6.1 Kesimpulan .............................................................................................................. 65
6.2 Saran ........................................................................................................................ 66
DAFTAR PUSTAKA ........................................................................................................ 67
LAMPIRAN ....................................................................................................................... 70
DAFTAR TABEL
Tabel 2.1 Contoh Peringkat waste .......................................................................................... 9
Tabel 2.2 Simbol-simbol dalam Value Stream Mapping ................................................... 12
Tabel 2.3 Penentuan rating Severity .................................................................................... 22
Tabel 2.4 Nilai Occurrence ................................................................................................ 23
Tabel 2.5 Nilai Detection ................................................................................................... 24
Tabel 4.1 Data Produksi Pallet NS 1210.2-4.T ................................................................... 38
Tabel 4.2 Data waktu siklus ................................................................................................ 38
Tabel 4.3 Data Jumlah Mesin.............................................................................................. 39
Tabel 4.4 Data Biaya Pemakaian Mesin ............................................................................. 39
Tabel 4.5 Harga Bahan Baku .............................................................................................. 40
Tabel 4.6 Data Inventory ..................................................................................................... 40
Tabel 4.7 Inventory Cost ..................................................................................................... 41
Tabel 4.8 Data Bahan Baku ............................................................................................... 42
Tabel 4.9 Rekapitulasi Hasil Kuesinoner Jenis Waste ....................................................... 42
Tabel 4.10 Perhitungan Processing Lead Time .................................................................. 44
Tabel 4.11 Labor Hour Rate .............................................................................................. 45
Tabel 4.12 Value Added Cost ............................................................................................. 45
Tabel 4.13 Non Value Added Cost ..................................................................................... 46
Tabel 4.14 Metric And Baseline Measurement .................................................................. 47
Tabel 4.15 Pembobotan Waste ........................................................................................... 50
Tabel 4.16 Root Cause Analysis waste Unnecessary Inventory ........................................ 52
Tabel 4.17 Failure Mode and Effect Analysis .................................................................... 54
Tabel 5.1 Perbandingan Current Dan Future Cost Integrated Value Stream .................... 64
DAFTAR GAMBAR
Gambar 2.1 Value Stream Mapping ................................................................................... 10
Gambar 2.2 Cost Integrated Value Stream Mapping ......................................................... 17
Gambar 3.1 Flowchart Metodologi Penelitian.................................................................... 26
Gambar 4.1 Struktur Organisasi PT Fajar Putra Plasindo................................................... 33
Gambar 4.2 Plastik Pallet NS 1210 2-4T Blue ....................................................... 34
Gambar 4.3 Operation Process Chart Plastic Pallet ......................................................... 35
Gambar 4.4 Current Cost Integrated Value Stream Map .................................................. 48
Gambar 4.5 Future Cost Integrated Value Stream Mapping ............................................. 58
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