Saputra, M. Wahyu (2026) ANALISIS LEAN MANUFACTURING MENGGUNAKAN VSM, VALSAT DAN KAIZEN UNTUK MENGURANGI WASTE PADA PRODUKSI JUMBO BAG DI PT KERTA RAJASA RAYA SIDOARJO. Undergraduate thesis, UPN "Veteran" Jawa Timur.
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Abstract
The manufacturing industry is required to enhance efficiency and quality; however, the jumbo bag production process at PT Kerta Rajasa Raya still contains various forms of waste. The results of the Current Value Stream Mapping indicate a total lead time of 515 minutes, with value-added time of 280 minutes, resulting in an initial Process Cycle Efficiency (PCE) of 54,37%. This indicates that a considerable proportion of non-value added activities still exists within the production process. Data from the period September 2024 to August 2025 show 3.973 defective units out of 386.803 units produced (an average of 1,323%), with 3.909 units requiring rework. In addition, waiting time accounts for 72 minutes, motion 60 minutes, and transportation 25 minutes (4,85% of total lead time), while overproduction averages 1.778 units per month, impacting inventory levels. Analysis using VALSAT and fishbone diagrams resulted in Kaizen-based improvement proposals, including scheduling machine preheating before the production process begins, designing a barcode-based start-up checklist, creating trays and organizing supporting tools in the work area to reduce motion, and establishing a structured sequence for printing machine list replacement. Based on the Future Value Stream Mapping, these proposed improvements are projected to reduce lead time to 420 minutes and increase PCE to 66,67%. Additionally, a digital dashboard using Looker Studio is proposed as a tool for continuous monitoring of production performance.
| Item Type: | Thesis (Undergraduate) | ||||||||
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| Subjects: | T Technology > TS Manufactures T Technology > TS Manufactures > TS 155-194 Production Management, Operations Management |
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| Divisions: | Faculty of Engineering > Departement of Industrial Engineering | ||||||||
| Depositing User: | M. Wahyu Saputra | ||||||||
| Date Deposited: | 30 Apr 2026 08:27 | ||||||||
| Last Modified: | 30 Apr 2026 08:27 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/51439 |
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