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All Journal Jurnal Teknik Industri Heuristic Teknika: Engineering and Sains Journal Jurnal Teknik Industri : Jurnal Hasil Penelitian dan Karya Ilmiah dalam Bidang Teknik Industri Jurnal Abdimas Berdaya : Jurnal Pembelajaran, Pemberdayaan dan Pengabdian Masyarakat JISO : Journal of Industrial and Systems Optimization Among : Jurnal Pengabdian Masyarakat JURNAL TEKNIK INDUSTRI Journal Serambi Engineering (JSE)
Ahmad Fatih Fudhla
Universitas Maarif Hasyim Latif
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Integrasi Lean DMAIC dan Circular Economy untuk Reduksi Waste pada Manufaktur Paving Block Retnowati, Dini; Fudhla, Ahmad Fatih; Puspita, Asri Dwi; Annurrada, Sofia
Jurnal Serambi Engineering Vol. 10 No. 4 (2025): Oktober 2025
Publisher : Faculty of Engineering, Universitas Serambi Mekkah

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Abstract

Waste is a significant challenge in the manufacturing industry, including small and medium enterprises (SMEs) engaged in paving block production. This study applies the Lean DMAIC (Define–Measure–Analyse–Improve–Control) methodology to identify, analyze, and reduce waste in the production process. A case study was conducted at a paving block factory in East Java, which has an annual production capacity of 119,400 m². Data were collected from production records, observations, and interviews conducted between September 2024 and August 2025. Analysis using a weighted Pareto diagram and Flow Process Mapping revealed that defect categories, although accounting for only 1.99% of total production, resulted in a significant accumulation of dead stock in the storage area. Through a Decision Matrix and a radar chart, a recycling strategy was selected as the improvement solution. This strategy was subsequently formalized into a Standard Operating Procedure (SOP) for managing rejected products, ensuring consistent implementation and adherence. Evaluation of the implementation over one month showed a 23.8% reduction in dead stock volume. These findings provide empirical evidence of the effectiveness of integrating Lean DMAIC with circular economy principles in the paving block industry, offering a practical framework that can be replicated in similar manufacturing sectors.
Critical Waste Reduction in Flexible Packaging Printing Process Using Lean-DMAIC Approach Mohamad Yayan Ramadani; Dini Retnowati; Ahmad Fatih Fudhla
Heuristic Vol 23, No 1 (2026)
Publisher : Fakultas Teknik Universitas 17 Agustus 1945 Surabaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30996/heuristic.v23i1.133442

Abstract

The printing process in flexible packaging manufacturing is highly sensitive to operational inefficiencies, as it involves machine setup, color adjustments, material handling, inspection activities, and coordination across departments. Inefficiencies in this process may lead to defects, work-in-process accumulation, increased waiting time, and reduced performance of the production flow. This study aims to identify, prioritize, and reduce critical waste in the printing process of a flexible packaging manufacturing system using the Lean-DMAIC approach. A quantitative case study was conducted using process flow, cycle time, lead time, production, and waste occurrence data collected from January to December 2025. In the define stage, Value Stream Mapping (VSM) was used to describe the production flow and identify process inefficiencies. In the measure stage, seven types of waste were quantified and prioritized using Pareto analysis. The analysis stage used Root Cause Analysis (RCA) and Failure Mode and Effects Analysis (FMEA) to identify root causes and assess risk levels using the Risk Priority Number (RPN). The results show that defects, inventory, and waiting are the dominant wastes, contributing to approximately 80% of total waste. Defects have the highest RPN value of 567, indicating the most critical problem. The proposed improvement actions reduced defect waste from 13.20% to 6.15%, inventory waste from 11.25% to 4.30%, and waiting waste from 6.49% to 3.95%. These findings indicate that integrating Lean-DMAIC, VSM, Pareto analysis, RCA, and FMEA provides a structured, effective approach to reducing critical waste in flexible packaging printing operations.
INDUSTRIAL AND SYSTEMS OPTIMIZATION IN THE ERA OF INTELLIGENT, RESILIENT, SUSTAINABLE, AND HUMAN-CENTERED INDUSTRY: AN EDITORIAL INSIGHT Asri Dwi Puspita; Ahmad Fatih Fudhla; Gempur Santoso
JISO : Journal of Industrial and Systems Optimization Vol. 9 No. 1 (2026): Juni 2026
Publisher : Universitas Maarif Hasyim Latif

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.51804/jiso.v9i1.i-xiii

Abstract

ABSTRACT Industrial and systems optimization is experiencing a significant shift from conventional efficiency-oriented approaches toward more intelligent, resilient, sustainable, and human-centered systems. This editorial insight examines the current direction of industrial and systems optimization amid rapid technological development, supply chain uncertainty, sustainability pressures, and the growing need for data-driven decision-making. The discussion highlights several emerging trends, including artificial intelligence, machine learning, digital twins, supply chain resilience, predictive maintenance, sustainable and multi-objective optimization, and Industry 5.0. These developments show that optimization is no longer limited to minimizing cost, reducing process time, or maximizing output. Instead, optimization should be understood as a broader systems approach that integrates data, technology, human factors, operational risk, environmental responsibility, and practical decision-making. This article also emphasizes the importance of clear problem formulation, transparent assumptions, reliable data, model validation, sensitivity analysis, and practical relevance in industrial optimization research. Within the scope of JISO: Journal of Industrial and Systems Optimization, this editorial insight encourages future studies that connect rigorous methods with real industrial problems, especially in manufacturing systems, supply chain and logistics, facility design, production planning, inventory control, occupational health and safety, ergonomics, sustainable manufacturing, maintenance, and decision analytics. The article concludes that the future of industrial and systems optimization lies in its ability to support systems that are not only efficient, but also adaptive, responsible, resilient, and beneficial for both industry and society. ABSTRAK Optimasi sistem dan industri mengalami pergeseran signifikan dari pendekatan berorientasi efisiensi konvensional menuju sistem yang lebih cerdas, tangguh, berkelanjutan, dan berpusat pada manusia. Wawasan editorial ini membahas arah optimalisasi industri dan sistem saat ini sebagai tanggapan terhadap perkembangan teknologi yang cepat, ketidakpastian rantai pasokan, tekanan keberlanjutan, dan meningkatnya kebutuhan akan pengambilan keputusan berbasis data. Diskusi ini menyoroti beberapa tren yang muncul, termasuk kecerdasan buatan, pembelajaran mesin, kembar digital, ketahanan rantai pasokan, pemeliharaan prediktif, pengoptimalan berkelanjutan dan multi-objektif, dan Industri 5.0. Perkembangan ini menunjukkan bahwa optimasi tidak lagi terbatas pada meminimalkan biaya, mengurangi waktu proses, atau memaksimalkan output. Sebaliknya, pengoptimalan harus dipahami sebagai pendekatan sistem yang lebih luas yang mengintegrasikan data, teknologi, faktor manusia, risiko operasional, tanggung jawab lingkungan, dan pengambilan keputusan praktis. Artikel ini juga menekankan pentingnya perumusan masalah yang jelas, asumsi transparan, data yang dapat diandalkan, validasi model, analisis sensitivitas, dan relevansi praktis dalam penelitian optimasi industri. Dalam lingkup JISO: Journal of Industrial and Systems Optimization, wawasan editorial ini mendorong studi masa depan yang menghubungkan metode ketat dengan masalah industri nyata, terutama dalam sistem manufaktur, rantai pasokan dan logistik, desain fasilitas, perencanaan produksi, kontrol inventaris, kesehatan dan keselamatan kerja, ergonomi, manufaktur berkelanjutan, pemeliharaan, dan analitik keputusan. Artikel tersebut menyimpulkan bahwa masa depan optimasi industri dan sistem terletak pada kemampuannya untuk mendukung sistem yang tidak hanya efisien, tetapi juga adaptif, bertanggung jawab, tangguh, dan bermanfaat bagi industri dan masyarakat.
Co-Authors Achmad Amiruddin Santoso Agus Hidayat ahmad yani Ahmad Yani Ahsan Muafa Anda Iviana Juniani Annurrada, Sofia Arkananta, Raditya Erlang Dini Retnowati Gusti Adriansyah Ika Widya Ardhyani Khoir, Muhammad Fathul Moch. Anshori Mohamad Yayan Ramadani Moses Laksono Singgih Muhammad Fathul Khoir Patdono Suwignjo Puspita, Asri Dwi Raditya Erlang Arkananta Ratna Ekasari Santoso, Achmad Amiruddin SN, Susilowati Indah Susilowati Indah SN Yudo Purnomo Yudo Purnomo, Yudo Yuyut Tri Prasetyo