Analisis Waste Overproduction dan Inventory Pada Proses Produksi Braket AC Menggunakan Metode Lean Manufacturing
(Studi Kasus: UD. Raja Ring)
DOI:
https://doi.org/10.55826/jtmit.v5i3.2116Keywords:
Lean Manufacturing, Kanban, 5S, Work-in-Process, OverproductionAbstract
Penelitian ini bertujuan untuk menganalisis sumber pemborosan akibat produksi berlebih dan penumpukan inventaris dalam proses produksi braket AC di UD. Raja Ring, serta mengusulkan strategi perbaikan berbasis *Lean Manufacturing* menggunakan pendekatan Kanban dan 5S. Value Stream Mapping (VSM) digunakan untuk mengidentifikasi pemborosan produksi dan mengevaluasi kinerja proses, sementara sistem Kanban dua kartu dirancang untuk mengendalikan inventaris Work-in-Process (WIP) dan mendukung transisi dari sistem produksi push ke sistem pull. Selain itu, metode 5S diusulkan untuk memperbaiki penataan tempat kerja dan efisiensi operasional di area pelapisan coating. Hasil penelitian menunjukkan bahwa proses produksi awal memiliki lead time sebesar 2.602 detik dan Process Cycle Efficiency (PCE) sebesar 53,9%, dengan rata-rata WIP sebanyak 233 set. Sistem Kanban yang diusulkan (permintaan 124 set/hari, kapasitas wadah 10 set, dan 18 kartu Kanban) berpotensi mengurangi rata-rata WIP sebesar 61,4% menjadi 90 set, sedangkan perbaikan 5S yang diusulkan meningkatkan efisiensi area pelapisan dari 33,3% menjadi 70,0% (p < 0,001). Temuan ini menunjukkan bahwa integrasi Kanban dan 5S secara efektif mengurangi pemborosan produksi, memperbaiki aliran material, dan meningkatkan efisiensi operasional pada UKM pengolahan logam.
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