Electronic Theses and Dissertation

Penelitian ini bertujuan untuk menganalisis penerapan Lean Manufacturing dalam meningkatkan produktivitas dan efisiensi biaya produksi di Pabrik Tahu Abi Makmur. Fokus utama penelitian adalah mengidentifikasi dan mengurangi pemborosan (waste) yang terjadi selama proses produksi tahu. Penelitian ini mengidentifikasi empat jenis pemborosan utama, yaitu waste of waiting berupa waktu tunggu yang lama pada proses perendaman kedelai, waste of transportation berupa pemindahan tahu ke meja pemotongan dan tempat penyimpanan sementara yang memiliki jarak cukup jauh, waste of motion berupa kegiatan memasukkan dan mengeluarkan selang yang memerlukan waktu beberapa menit, serta waste of defect berupa hasil tahu yang menggumpal dan bentuknya miring. Dalam mengatasi permasalahan tersebut, dilakukan beberapa langkah perbaikan melalui pendekatan Lean Manufacturing, antara lain perancangan Value Stream Mapping (VSM) yang terdiri dari Current State Map (CSM) dan Future State Map (FSM), Identifikasi Waste, penyusunan Fishbone Diagram, serta analisis menggunakan Process Activity Mapping (PAM). Rekomendasi perbaikan yang dihasilkan mencakup pengaturan suhu air perendaman pada kisaran 40–50°C, re-design layout stasiun kerja untuk memperpendek jarak antar proses, penambahan alat bantu berupa troli, serta penerapan prinsip Built-in Quality guna meminimalkan cacat produk. Hasil penelitian menunjukkan adanya peningkatan produktivitas sebesar 17,546% dan efisiensi biaya produksi sebesar 15%. Dengan demikian, implementasi Lean Manufacturing terbukti efektif dalam mengoptimalkan proses produksi, serta diharapkan dapat menjadi acuan strategis bagi perusahaan dalam meningkatkan daya saing dan kinerja operasional.
Kata Kunci: Produktivitas, Efisiensi Biaya Produksi, Lean Manufacturing, Pabrik Tahu

This study aims to analyze the implementation of Lean Manufacturing in improving productivity and cost efficiency at Tahu Abi Makmur Factory. The main focus of the research is to identify and reduce waste that occurs during the tofu production process. The study identifies four main types of waste waste of waiting referring to the long waiting time during the soybean soaking process, waste of transportation involving the movement of tofu to the cutting table and temporary storage area located at a considerable distance, waste of motion related to the activity of inserting and removing hoses which takes several minutes, and waste of defect which results in clumped or unevenly shaped tofu. To address these issues, several improvement actions were taken using Lean Manufacturing approaches, including the development of Value Stream Mapping (VSM) consisting of the Current State Map (CSM) and Future State Map (FSM), Waste Identification, construction of a Fishbone Diagram, and analysis through Process Activity Mapping (PAM). The recommended improvements include setting the soaking water temperature to around 40–50°C, redesigning the workstation layout to reduce the distance between processes, adding supporting tools such as trolleys, and applying the Built-in Quality principle to minimize product defects. The results of the study show a 17.546% increase in productivity and a 15% improvement in production cost efficiency. Therefore, the implementation of Lean Manufacturing is proven to be effective in optimizing the production process and is expected to serve as a strategic reference for the company in enhancing its competitiveness and operational performance. Keywords: Productivity, Production Cost Efficiency, Lean Manufacturing, Tofu Factory