Electronic Theses and Dissertation

PT. Triputra Aceh Conblock merupakan perusahaan yang bergerak di bidang produksi paving block. Dalam proses produksinya masih ditemukan berbagai pemborosan yang menurunkan efisiensi aliran proses produksi, dengan tingkat produk cacat mencapai 10,14% dari total produksi. Penelitian ini bertujuan untuk memetakan aliran produksi, mengidentifikasi jenis pemborosan (waste), serta memberikan usulan perbaikan melalui penerapan Lean Manufacturing menggunakan metode Value Stream Mapping (VSM) dan Value Stream Analysis Tools (VALSAT) melalui Process Activity Mapping (PAM) sebagai alat analisis aktivitas produksi. Penerapan Value Stream Mapping (VSM) dan Process Activity Mapping (PAM) berhasil memetakan aliran proses produksi serta mengidentifikasi aktivitas Value Added (VA), Non-Value Added (NVA), dan Necessary Non-Value Added (NNVA). Hasil Current State Mapping menunjukkan total waktu proses produksi sebesar 982,553 menit. PAM menunjukkan bahwa aktivitas proses produksi terdiri atas 92,05% Value Added (VA), 1,59% Non-Value Added (NVA), dan 6,37% Necessary Non-Value Added (NNVA). Identifikasi waste menunjukkan adanya empat jenis pemborosan, yaitu defect, waiting, motion, dan transportation. Berdasarkan hasil PAM, waste motion merupakan pemborosan dominan dengan persentase 58,55%, sedangkan waste defect ditunjukkan oleh tingkat cacat produk sebesar 10,14% dari total produksi. Analisis penyebab pemborosan dilakukan menggunakan Cause and Effect Diagram, kemudian dirumuskan usulan perbaikan berupa penerapan Built-in Quality (BIQ), optimalisasi penggunaan trolley dan gerobak dorong, penataan cetakan agar lebih mudah dijangkau operator, serta perbaikan metode kerja pada proses produksi. Hasil Future State Mapping menunjukkan penurunan total waktu proses produksi dari 982,553 menit menjadi 968,540 menit atau berkurang sebesar 14,013 menit (1,43%). Usulan perbaikan tersebut mampu mengurangi pemborosan pada aktivitas waiting, motion, dan transportation sehingga meningkatkan efisiensi aliran proses produksi paving block di PT. Triputra Aceh Conblock.

Kata Kunci : Lean Manufacturing, Waste, Value Stream Mapping, Current State Mapping, Process Activity Mapping, Cause and Effect Diagram, Future State Mapping, Paving Block.

PT. Triputra Aceh Conblock is a company engaged in paving block production. However, several types of waste are still present in its production process, reducing production flow efficiency, with defective products accounting for 10,14% of total production. This study aims to map the production flow, identify the types of waste, and propose improvement strategies through the implementation of Lean Manufacturing using Value Stream Mapping (VSM) and Value Stream Analysis Tools (VALSAT), with Process Activity Mapping (PAM) employed as the activity analysis tool. The application of VSM and PAM successfully mapped the production flow and identified Value Added (VA), Non-Value Added (NVA), and Necessary Non-Value Added (NNVA) activities. The Current State Mapping results showed a total production lead time of 982,553 minutes. PAM analysis indicated that production activities consisted of 92,05% VA, 1,59% NVA, and 6,37% NNVA. Waste identification revealed four types of waste, namely defect, waiting, motion, and transportation. Based on PAM results, motion was identified as the dominant waste, accounting for 58,55% of total time based waste, while defect was indicated by a defect rate of 10,14% of total production. The causes of waste were analyzed using a Cause and Effect Diagram, and improvement proposals were developed, including the implementation of Built-in Quality (BIQ), optimization of trolley and handcart utilization, rearrangement of molds to improve operator accessibility, and improvements in production work methods. The Future State Mapping results showed a reduction in total production lead time from 982,553 minutes to 968,540 minutes, representing a decrease of 14,013 minutes (1,43%). These improvements were able to reduce waste related to waiting, motion, and transportation, thereby improving the efficiency of the paving block production flow at PT. Triputra Aceh Conblock. Keyword : Lean Manufacturing, Waste, Value Stream Mapping, Current State Map, Process Activity Mapping, Cause and Effect Diagram, Future State Mapping, Paving Block.