Ramadhan, Muhammad Afif (2026) ANALISIS PEMBOROSAN PROSES PRODUKSI PESTISIDA DENGAN METODE LEAN SIX SIGMA DAN FAILURE MODE EFFECT ANALYSIS DI PT PETROKIMIA KAYAKU. Undergraduate thesis, Universitas Pembangunan Nasional "Veteran" Jawa Timur.
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Abstract
Indonesia is referred to as an agrarian country due to its abundant natural resources derived from the agricultural and plantation sectors. These sectors play a crucial role in supporting sustainable national food security. Pesticides are chemical substances, microorganisms, or viruses used to control and prevent various pests, including insects, plant diseases, weeds, and other harmful organisms. PT Petrokimia Kayaku is a company that produces various types of pesticides, namely liquid, powder, and granular pesticides. Among these products, powder pesticides exhibit the highest defect rate of 25.6%. In the powder pesticide production process, Mipcinta has the largest production capacity, and several types of waste were identified along the production flow, including product defects totaling 88,221 kg units, consisting of caking defects, contaminated products, non standard product weight, and non-uniform mixing. Another issue identified was a high production lead time of 763.11 minutes. This study aims to reduce waste and minimize lead time by applying the Lean Six Sigma method using the DMAIC approach and Failure Mode and Effect Analysis (FMEA). The results indicate that the three dominant types of waste are defects, waiting time, and transportation. The implementation of proposed improvements successfully reduced the lead time to 681.38 minutes. The average sigma level was 3.28 with a DPMO value of 37,519, which is considered good compared to the average industrial performance in Indonesia. The recommended improvements include providing employee training, conducting routine machine inspections, increasing the number of forklifts, and designing a dedicated forklift parking layout to improve access to the production area. Through the implementation of process activity mapping and big picture mapping, production efficiency increased from 52,59% to 58,90%. Keywords: FMEA, Lean Six Sigma, Pesticides, Waste
| Item Type: | Thesis (Undergraduate) | ||||||||
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| Subjects: | T Technology > T Technology (General) T Technology > T Technology (General) > T55.4-60.8 Industrial engineering. Management engineering T Technology > TS Manufactures T Technology > TS Manufactures > TS 155-194 Production Management, Operations Management T Technology > TS Manufactures > TS 180-TS180.8 Material Handling |
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| Divisions: | Faculty of Engineering > Departement of Industrial Engineering | ||||||||
| Depositing User: | Muhammad Afif Ramadhan | ||||||||
| Date Deposited: | 24 Feb 2026 03:19 | ||||||||
| Last Modified: | 24 Feb 2026 03:19 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/49693 |
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