Agustina, Endang (2025) Analisa Penerapan Lean Manufacturing, VSM, FMEA dan RCA Untuk Mengurangi Pemborosan (Waste) Pada Proses Produksi Pupuk Phonska IV PT Petrokimia Gresik. Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
Phonska IV fertilizer is one type of subsidized compound fertilizer produced by PT Petrokimia Gresik, containing main nutrients such as Nitrogen, Phosphorus, Potassium, and Sulfur. This study aims to reduce waste in the production process using the Lean Manufacturing approach with several methods, namely Value Stream Mapping (VSM), Failure Mode and Effect Analysis (FMEA), and Root Cause Analysis (RCA). Based on the results of the analysis using VSM and VALSAT, four types of waste were found to be the most dominant, namely waiting, defect, excess processing, and overproduction. These four types of waste have a negative impact on production efficiency and quality. Several proposed improvements that were implemented include the use of raw material checklists, validation of materials before mixing, periodic machine maintenance, and demand forecasting based on actual data. After the improvements were implemented, the production lead time was successfully reduced from 215 minutes to 150 minutes or increased its efficiency by 30.2%. This research is important because it is able to provide real solutions to increase the efficiency of the production process in the fairly complex subsidized fertilizer industry. Theoretically, this research contributes to the development of an integrated lean manufacturing application model as a systematic approach to reducing waste in process-based manufacturing industries.
| 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: | Endang Agustina - | ||||||||
| Date Deposited: | 20 Jun 2025 03:07 | ||||||||
| Last Modified: | 07 Jul 2025 03:28 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/38779 |
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