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All Journal Jurnal Teknik Industri KAPAL Jurnal Ilmu Pengetahuan dan Teknologi Kelautan TEKMAPRO Journal of Industrial Engineering and Management JISI UMJ (Jurnal Integrasi Sistem Industri UMJ) REKAYASA Sistemasi: Jurnal Sistem Informasi Journal of Industrial Engineering Management EKONOMIS : Journal of Economics and Business STRING (Satuan Tulisan Riset dan Inovasi Teknologi) Matrik : Jurnal Manajemen dan Teknik Industri Produksi Jurnal Teknik Industri Terintegrasi (JUTIN) Academia Open Nusantara Science and Technology Proceedings Indonesian Journal of Industrial Engineering & Management Juminten : Jurnal Manajemen Industri dan Teknologi Journal La Lifesci Journal La Multiapp Indonesian Journal of Innovation Studies JAMBURA: JURNAL ILMIAH MANAJEMEN DAN BISNIS Jurnal Teknik Mesin, Industri, Elektro dan Informatika Jurnal Kendali Teknik dan Sains IIJSE Journal Serambi Engineering (JSE)
Rr. Rochmoeljati
Department Of Industrial Engineering, Faculty Of Engineering And Sains, Universitas Pembangunan Nasional Veteran Jawa Timur, Surabaya 60294, Indonesia
Aerospace Engineering Agriculture, Biological Sciences & Forestry Arts Humanities Automotive Engineering Chemical Engineering, Chemistry & Bioengineering Chemistry Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Earth & Planetary Sciences Economics, Econometrics & Finance Education Electrical & Electronics Engineering Energy Engineering Environmental Science Immunology & microbiology Industrial & Manufacturing Engineering Languange, Linguistic, Communication & Media Law, Crime, Criminology & Criminal Justice Library & Information Science Materials Science & Nanotechnology Mathematics Mechanical Engineering Medicine & Pharmacology Physics Social Sciences Other

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Analysis of Waste in Electronic ID Card Services with Lean Service and Root Cause Analysis Methods Ahyaliya, Marsya Laila; Rochmoeljati, Rr.
Journal La Multiapp Vol. 6 No. 6 (2025): Journal La Multiapp
Publisher : Newinera Publisher

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37899/journallamultiapp.v6i6.2446

Abstract

Optimal service is essential to ensure citizen satisfaction in managing population administration. This study analyzes waste in the Electronic ID Card (KTP Elektronik) service process using the Lean Service and Root Cause Analysis (RCA) methods. The research was conducted at Office X through direct observation, interviews, and the distribution of questionnaires to eight respondents directly involved in the service process. The collected data included service process flows, activity durations, waste identification, and their root causes. Using the Value Stream Mapping (VSM) method and VALSAT tools, it was found that the total lead time was 1,953 seconds, but only 238 seconds (13%) were categorized as value-added activities. The dominant types of waste identified included waiting, duplication, defects, and unnecessary movement. Based on the score calculation results, Process Activity Mapping (PAM) was selected as the main VALSAT tool. RCA analysis using fishbone diagrams and the 5 Whys method revealed root causes such as inaccurate queue time estimates, repeated data entry, lack of supporting facilities, and inefficient workplace layout. The improvement recommendations include optimizing the online queuing system and adding supporting equipment such as tripods and printers. After improvements were implemented, the service time was reduced to 898 seconds, and the proportion of value-added activities increased to 27%, indicating that the application of Lean Service and RCA was effective in improving service efficiency.
Waste Analysis in Connection Clamp Production Process with Lean Manufacturing and Failure Mode Effect Analysis Hidayatulloh, Faishal; Rochmoeljati, Rr.
Journal La Multiapp Vol. 7 No. 1 (2026): Journal La Multiapp
Publisher : Newinera Publisher

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37899/journallamultiapp.v7i1.2820

Abstract

UD H and M Electric is a manufacturing company engaged in the production of medium voltage overhead line (SUTM) components, one of its products is the Connection Clamp. The purpose of this study is to determine the level of waste that occurs and provide suggestions for improvements to reduce waste. The research data used is questionnaire data with respondents who meet the qualifications and know the entire flow of the Connection Clamp production process, as well as waste data that occurs during the production process. To determine the level of waste that occurs and provide suggestions for improvements, the Waste Assessment Model, Process Activity Mapping, Fishone Diagram, and Failure Mode and Effect Analysis methods are used. In the Waste Assessment Model method, the top three critical levels of waste were obtained, namely waste defect of 19.55%, waste motion of 16.88%, waste transportation of 16.10%. In the Failure Mode and Effect Analysis, the Risk Priority Number (RPN) value was obtained from the top three wastes with each sub-waste, namely waste motion sub-waste lifting products manually with a score of 280, waste motion sub-waste rearranging before the process with a score of 240, waste transport, namely the distance of the work station is less than optimal with a score of 200, waste reject sub-waste cracked plates with a score of 168, waste Defect, namely imperfect layers with a score of 168.
Theory of Constraint and Drum Buffer Rope Increase Shoe Production Throughput: Teori Kendala dan Drum Buffer Rope Meningkatkan Produktivitas Produksi Sepatu Rahmawati, Dea; Rochmoeljati, Rr.
Indonesian Journal of Innovation Studies Vol. 27 No. 1 (2026): January
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/ijins.v27i1.1891

Abstract

General Background: Production systems frequently experience capacity imbalances that disrupt material flow and reduce throughput, particularly in small- and medium-scale manufacturing environments. Specific Background: UD Anugrah, a footwear manufacturer specializing in children’s shoes, faces recurring work-in-progress accumulation caused by unequal capacities among production workstations. Knowledge Gap: Prior studies have widely applied the Theory of Constraints, yet empirical applications integrating Drum-Buffer-Rope scheduling within the footwear manufacturing sector remain limited. Aims: This study aims to optimize production capacity at UD Anugrah by applying the Theory of Constraints integrated with the Drum-Buffer-Rope concept to identify, manage, and resolve system bottlenecks. Results: Sewing and Injection workstations were identified as primary constraints; optimization through linear programming, flow synchronization, and selective capacity elevation increased monthly throughput from IDR 88,166,810 to IDR 91,707,000, representing a 3.86% increase, while financial analysis yielded a positive Net Present Value of IDR 61,881,704 and a Payback Period of 3.41 years. Novelty: This research presents an integrated TOC–DBR application within a shoe manufacturing context, supported by quantitative throughput and investment feasibility analysis. Implications: The findings demonstrate that structured constraint management and DBR-based flow control provide a practical framework for improving production performance and investment decision-making in small- and medium-scale manufacturing enterprises. Highlights: Sewing and Injection stations were consistently identified as system constraints across multiple production periods. Linear programming supported optimal product mix allocation under limited workstation capacity. Financial evaluation confirmed that selective machine addition was economically feasible within the system lifespan. Keywords : Theory of Constraints, Drum Buffer Rope, Production Capacity, Shoe Manufacturing, Bottleneck Analysis
Lean Six Sigma and FMEA for Pesticide Production Waste Reduction: Lean Six Sigma dan FMEA untuk Mengurangi Limbah Produksi Pestisida Ramadhan, Muhammad Afif; Rochmoeljati, Rr.
Indonesian Journal of Innovation Studies Vol. 27 No. 1 (2026): January
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/ijins.v27i1.1895

Abstract

General Background Pesticide manufacturing plays a critical role in supporting agricultural productivity, yet complex production systems frequently generate operational waste and product defects. Specific Background PT XYZ produces multiple pesticide variants, with powder pesticides showing the highest defect proportion during the October 2024–September 2025 period, indicating inefficiencies within the production process. Knowledge Gap Despite recurring defects and extended lead time, systematic waste identification and structured failure risk prioritization had not been comprehensively applied in this production context. Aims This study aimed to identify dominant waste types, evaluate process performance, and formulate improvement recommendations using Lean Six Sigma integrated with Failure Mode and Effect Analysis. Results The analysis identified defects, waiting, transportation, and environmental health and safety as dominant wastes. Lead time was reduced from 763.11 minutes to 681.38 minutes through the elimination of non-value-added activities. Process performance showed an average DPMO of 37,519.68 with a sigma level of 3.28, alongside an increase in Process Cycle Efficiency from 59.55% to 66.69%. FMEA results indicated the highest Risk Priority Numbers were associated with non-standard product weight and product clumping caused by operator inconsistency and suboptimal machine performance. Novelty This study presents an integrated application of Lean Six Sigma and FMEA to map waste sources and prioritize failure risks within a pesticide powder production system. Implications The findings provide structured improvement recommendations, including operator training, standardized machine settings, and routine maintenance, offering a data-driven reference for manufacturing process optimization in similar industrial settings. Highlights: Defect-related losses constituted the largest proportion of inefficiencies in the studied manufacturing flow. Quantitative performance metrics demonstrated measurable reductions in processing time and defect opportunity rates. Risk prioritization revealed machine condition and operator consistency as dominant contributors to quality deviation. Keywords: Pesticides, Waste, Lean Six Sigma, FMEA
Co-Authors Adham Roihan Azriel Irfani Afriza, Ajeng Agustina, Mega Ahyaliya, Marsya Laila Alief Wahyu Pratama Alvionita, Selvi Amalia, Rochmatul Anasari, Sofia Fitri Annandita, Alifia Rizky Benedictus Vibriyanto Bagas Prakosa Berliana Dian Novitasari Brilian, Delinda Budiani, Dian Nissa Fitri Bustomy, Andrean Chori Dwi Azizah Christabela Jesselyn Dimas Wandhika D Dira Ernawati Endang Pudji Widjajati Erlina Erlina Faizal, M. Rizki Nur Fenny Novianti Ferina Indah Lusiana Ferraldo Kusuma Artono Putra Fibio Isnando Hariatmaja Pradana Fuadah, Layin Hidayatulloh, Faishal Iriani Iriani Isna Nugraha Ivonne Rakha Salsabila Kamal Husein Khusnun Nabila Mardila Nur Imamah Maunah, Dewi Aisarunnisa' Meisufi, Ruro Wiranti Moch Taufik Hidayat Mochamad Ismail Zakaria Muhammad Hadziqul Afkar Muhammad Rizki Kurniawan Nafa Artha Cahaya Mulia Nafa Artha Cahaya Mulia Nugraha, Isna Nugroho, Rosa Novarian Agninditya Pradana, Billy Gandis Prakosa, Albertus Adriyanto Satrio Pramudya, Kaka Arya Primadhiya, Fairuzzayyan Putra, M. Rizqy Ifaldhi Raditya Dwi Firmansyah Raditya Y E Rahmawati, Dea Ramadhan, Muhammad Afif Ramadhani, Muthia Dita Rauhul Rahman Adam Sinaga, Boriski Sinta Dewi Subono, Muhammad Wibbie Wiweka Syarifah, Faranisa Aulia Ar Rahma Tiara Nuriyah Sani Tranggono Tranggono Valentino, Eki Vaundra Cunning Hangesthi Widyarsa, Destiara Nabila Widyawati, Diana Ya Fachrul Rasyid Yustina N Yustina Ngatilah Zella Azzahra Achmadani