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All Journal Unistek: Jurnal Pendidikan dan Aplikasi Industri Science and Education Journal
Sita Kurniaty Ratoko
Tangerang Raya University
Humanities Automotive Engineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Education Electrical & Electronics Engineering Industrial & Manufacturing Engineering Social Sciences

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Penerapan Lean manufactturing Berbasis Value Stream Mapping (VSM), Failure Mode and Effect Analysis (FMEA) Untuk Mengurangi Downtime Cleaning dan Penggunaan Sodium Hydroxide di PT TES Baharui Gea; Sita Kurniaty Ratoko; Rakay Edhiargo Toyosito; Lifia Citra; Abimanyu Abimanyu
UNISTEK Vol. 13 No. 2 (2026): Agustus 2026 - Februari 2027
Publisher : UNIVERSITAS ISLAM SYEKH YUSUF TANGERANG

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33592/unistek.v13i2.8833

Abstract

The Cleaning In Place (CIP) process on Line 1 plays an important role in maintaining equipment cleanliness and ensuring product safety. However, excessive Cleaning Downtime increases production Downtime and Sodium Hydroxide (NaOH) consumption. This study aims to identify waste in the CIP process, determine the main causes of excessive Cleaning Downtime, and develop and implement improvement Actions to enhance Cleaning effectiveness. The methods used include Value Stream Mapping (VSM), Fishbone Diagram, Failure Mode and Effects Analysis (FMEA), and 5W1H. VSM results indicated that Cleaning Activities were classified as Non-Value-Added (NVA) Activities and significantly contributed to Downtime. FMEA identified the main causes of excessive Cleaning Downtime as the absence of nozzle valve covers (RPN=512), elevated machine positions that hinder inspections (RPN=448), insufficient awareness briefings (RPN=392), CIP frequency based on routine prActices (RPN=294), and the absence of NaOH usage records (RPN=252). Improvement Actions were developed using the 5W1H method and implemented through the installation of nozzle valve covers, CIP effectiveness verification, team awareness briefings, revision of the CIP matrix frequency, and NaOH usage monitoring. The implementation results showed that Cleaning frequency decreased from two times to one time per month, Cleaning Downtime decreased from 45.33 hours to 22.67 hours per month, and NaOH consumption decreased from 300 kg to 150 kg per month. These improvements successfully enhanced Cleaning effectiveness and chemical usage efficiency.
Komparasi Lingkungan Termal Gedung Baru Dan Lama Terhadap Heat Strain Operator Press Rubber Menggunakan HI Dan PSI Di PT XYZ M. Alfarizi; Angga Widyas Swara; Sita Kurniaty Ratoko
Science and Education Journal (SICEDU) Vol 5 No 3 (2026): Science and Education Journal 2026
Publisher : LPPM Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/sicedu.v5i3.1141

Abstract

The footwear manufacturing industry inherently involves physical hazards in the form of exposure to a hot working climate, particularly in the press rubber process that utilizes high-temperature heating machines. This study aims to measure and compare the level of heat strain experienced by operators in two production facilities with different ventilation systems, namely the New Building (mechanically ventilated) and the Old Building (naturally ventilated) at PT XYZ. The evaluation was conducted by combining environmental indicators using the Heat Index (HI) and internal physiological load indicators via the Physiological Strain Index (PSI). This comparative quantitative study involved 30 Shift 1 operators (15 operators per building) over a 15-day observation period. The parameters measured included air temperature, relative humidity, heart rate, skin surface temperature, as well as the Subjective Fatigue Assessment (SFA) questionnaire. The results indicated a highly significant disparity in thermal loads. At the peak hour (13:00 WIB), the Heat Index in the New Building was recorded at 48.8°C (Danger Category) with an average PSI of 4.06 (Moderate Strain). In contrast, the absence of mechanical air circulation in the Old Building led to extreme heat stagnation, causing the Heat Index to surge to 66.2°C (Extreme Danger Category) and elevating the average PSI to 6.25 (High Strain). These critical conditions in the Old Building were subjectively validated, revealing that 80% of the operators experienced decreased cognitive alertness and dizziness, thereby increasing the risk of human error. As a mitigation strategy, improvements in the Occupational Health and Safety (OHS) hierarchy are recommended. These include engineering controls through the installation of Canopy Hood-type Local Exhaust Ventilation (LEV), the implementation of structured micro-breaks, and the provision of Personal Protective Equipment (PPE) such as Phase Change Cooling Vests specifically for operators in the Old Building.
Co-Authors Abimanyu Abimanyu Angga Widyas Swara Baharui Gea Lifia Citra M. Alfarizi Rakay Edhiargo Toyosito