Upaya Optimalisasi Proses dengan Pendekatan Value Stream Mapping dan Kaizen Untuk Identifikasi di PT XYZ

Abstract

Abstract - The development of the manufacturing industry requires companies to reduce waste to remain competitive. This study aims to identify, analyze, and minimize non-value-added activities (waste) through continuous improvement (Kaizen) to increase company efficiency and productivity. This study uses qualitative and quantitative methods. The stages begin with value stream visualization using Value Stream Mapping (VSM), which produces Current State Mapping (CSM). In-depth analysis is conducted through Process Activity Mapping (PAM), questionnaires distributed to production employees (10 respondents) to identify the severity of waste, and Cause-Effect Diagrams to determine the root cause. Based on the analysis of VSM, PAM, and questionnaires (with the highest score of 520), it was found that the most dominant types of waste were transportation waste and waiting waste. This waste stems from the distance between work stations that is too far, which increases material movement time, as well as the existence of bottlenecks due to the limited capacity of the proofing machine. To address these problems, proposed improvements were designed in Future State Mapping (FSM) and conceptualized through Kaizen actions. The proposed improvements include (1) adding an electric pulley transporter to minimize transportation waste, (2) implementing Kaizen 5S (specifically the Seiton/Arrangement principle) to rearrange the layout of the production area, and (3) adding one proofing machine unit to eliminate the waiting time bottleneck. The main conclusion shows that the implementation of the proposed VSM-based Kaizen improvements will make the production process flow more efficient, successfully reduce waiting time, and be able to improve the company's overall productivity performance.

Keywords: waste, Value Stream Mapping (VSM), kaizen, lean manufacturing, bottleneck