Gairwyn, Shannon Viona (2026) Analisis Waste Proses Produksi di PT Harapan Sejahtera Karya Utama Dengan Metode Lean Manufacturing Dan Failure Mode and Effect Analysis (FMEA). Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
PT Harapan Sejahtera Karya Utama is a plastic manufacturing company that produces Polypropylene (PP), Polyethylene (PE), and High-Density Polyethylene (HDPE), including HDPE plastic bags sized 15×30 cm. The production process consists of material mixing, extrusion, forming, cutting, sealing, packaging, and finished goods storage. Based on company data, the defect rate of HDPE plastic bags reaches 7.02% (120.73 tons out of a total production of 1,721 tons), which is significantly higher than the company’s standard of 3%. In addition, several types of waste were identified, including waiting (59.39 minutes), unnecessary motion (7.49 minutes), overprocessing (7.12 minutes), and unnecessary transportation (2.66 minutes), as well as indications of unnecessary inventory and overproduction due to work-in-process (WIP) accumulation. These conditions indicate a high level of non-value-added activities and an inefficient production flow. Therefore, this study aims to identify waste and propose improvement solutions using the Lean Manufacturing approach. The analysis is conducted using Value Stream Mapping (VSM) and Process Activity Mapping (PAM) to map activities and process times, supported by a fishbone diagram (6M) and Failure Mode and Effects Analysis (FMEA) to determine risk priorities. The results show seven types of waste, with the highest priorities being defects (RPN 441), waiting (RPN 336), unnecessary motion (RPN 245), and overprocessing (RPN 224). The implementation of improvement proposals reduces the number of activities from 39 to 31 and decreases the lead time from 214.94 minutes to 151.14 minutes. Through these improvements, non-value-added (NVA) activities are eliminated, and the Process Cycle Efficiency (PCE) increases from 45.42% to 64.59%. These results indicate that the implementation of Lean Manufacturing significantly improves the efficiency and effectiveness of the production process flow.
| Item Type: | Thesis (Undergraduate) | ||||||||
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| Subjects: | T Technology > T Technology (General) > T55.4-60.8 Industrial engineering. Management engineering T Technology > TS Manufactures |
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| Divisions: | Faculty of Engineering > Departement of Industrial Engineering | ||||||||
| Depositing User: | Shannon Gairwyn | ||||||||
| Date Deposited: | 30 Apr 2026 08:05 | ||||||||
| Last Modified: | 30 Apr 2026 08:05 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/51448 |
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