REDUCTION OF WASTE ON PLASTIC LABEL PRODUCTION WITH LEAN MANUFACTURING APPROACH
A. Anas Haikal (a*) Moses L. Singgih
Magister Manajemen Teknologi, ITS Surabaya
Jl. Raya ITS, Keputih, Kec. Sukolilo, Kota SBY, Jawa Timur 60111
(a*) anashaikal9[at]gmail.com
Abstract
Plastic label company is one of the manufacturers that provides plastic label products in the form of Flexible Packaging. Company production data in 2018 show that there is a fluctuation in the amount of Defect. Not only that, the defect value is always above the maximum limit applied by the company which is a maximum of 8%. Data on the number of compliance with Flexible Packaging requests from 2015 to 2018 continues to decline. Increasing productivity by reducing waste becomes one of the things that need to be done to increase production. Waste analysis in the Flexible Packaging production process is carried out by the Seven Waste Assessment (SWA) and Waste Relationship Matrix (WRM) methods. SWA is used to identify waste, while WRM is used to determine the level of interrelation between waste. Also carried out weighting of each waste with the Waste Assessment Questionnaire (WAQ) method. From the weighting of waste chosen appropriate tools using the VALSAT method. From this study produced four priority wastes that will be recommended to be reduced, namely Motion, Defect, Inventory and Transportation. The recommended improvement for Waste Motion is to implement Quality Improvement, namely the application of 5S principles. Whereas recommendations for improvement for waste transportation by changing the layout of the factory engine using the U-Shape Layout principle. Reduce improvements to Inventory waste by applying the principles and Economic Order Quantity (EOQ) equations to control raw materials and adding lamination machines to reduce WIP Printing Inventory. Meanwhile, to reduce waste Defect, it is recommended that the Poka-Yoke principle be applied in the production of Flexible Packaging.
Keywords: : Defect, Production, Plastic Label, SWA, VALSAT, Waste, WAQ, WRM
Topic: Operation Management