Electronic Theses and Dissertation

Produksi tempe yang efisien menjadi penting untuk memenuhi kebutuhan konsumen sekaligus menjaga keberlanjutan usaha, terutama pada skala Usaha Mikro, Kecil, dan Menengah (UMKM). Penelitian ini dilakukan di Pabrik Tempe Bandung yang berlokasi di Aceh Besar dengan tujuan untuk mengidentifikasi dan meminimasi pemborosan (waste) dalam proses produksinya. Pendekatan yang digunakan adalan konsep Lean Manufacturing, dengan metode utama Value Stream Mapping (VSM), Waste Assessment Model (WAM), serta analisis lanjutan menggunakan 5 whys dan Failure Mode and Effect Analysis (FMEA). Identifikasi dilakukan terhadap tujuh jenis pemborosan (seven waste) yaitu overproduction, inventory, defect, motion, transportation, process, dan waiting. Hasil analisis menunjukkan bahwa pemborosan dominan adalah waste motion dengan nilai 21,94%. Melalui pengolahan data dari observasi lapangan, wawancara, dan kuesioner yang disebarkan kepada 6 responden, dilakukan analisis akar penyebab dan penilaian resiko menggunakan FMEA. Waste motion memiliki nilai Risk Priority Number (RPN) tertinggi dengan nilai 490. Hasil tersebut diusulkan untuk perbaikan melalui Future State Mapping dengan cara pengurangan nilai lead time dari aktivitas pemindahan kedelai antar stasiun kerja dengan pengurangan lead time sebesar 22,08 menit.
Kata kunci: Tempe, Value Stream Mapping, Waste Assessment Model, Waste Relationship Matrix (WRM), Waste Assessment Questionnaire (WAQ), 5 whys, FMEA.

Efficient tempeh production is essential to meet consumer demands while ensuring business sustainability, especially for Micro, Small, and Medium Enterprises (MSMEs). This study was conducted at Pabrik Tempe Bandung, located in Aceh Besar, with the aim of identifying and minimizing waste in its production process. The approach used is based on Lean Manufacturing principles, with the main methods being Value Stream Mapping (VSM), the Waste Assessment Model (WAM), and further analysis using the 5 Whys and Failure Mode and Effect Analysis (FMEA). The study focuses on identifying seven types of waste: overproduction, inventory, defects, motion, transportation, overprocessing, and waiting. The analysis results indicate that the most dominant type of waste is motion waste, accounting for 21.94%. Data was collected through field observations, interviews, and questionnaires distributed to six respondents. Root cause analysis and risk assessment were carried out using FMEA. Motion waste was found to have the highest Risk Priority Number (RPN) of 490. Based on these findings, improvement suggestions were made through the development of a Future State Map by reducing lead time in the soybean transfer process between workstations, achieving a lead time reduction of 22,08 minutes. Keyword: Tempeh, Value Stream Mapping, Waste Assessment Model, Waste Relationship Matrix (WRM), Waste Assessment Questionnaire (WAQ), 5 whys, FMEA.