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Ahmad
Universitas Tarumanagara
Computer Science & IT Control & Systems Engineering Engineering Industrial & Manufacturing Engineering Library & Information Science Mechanical Engineering Other

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Peningkatan Produktivitas UMKM Konveksi Berbasis Lean Manufacturing pada Sistem Make to Order (MTO) Rio Saputra; Ahmad; Meirista Wulandari
Jurnal Sains dan Teknologi Vol. 1 No. 3 (2026): Edisi: April-Juni
Publisher : Pustaka Bangsa Indonesia

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Abstract

Industri konveksi sebagai bagian dari sektor UMKM memiliki peran penting dalam perekonomian Indonesia, namun masih menghadapi berbagai permasalahan seperti rendahnya produktivitas, tingginya tingkat pemborosan, serta sistem manajemen produksi yang belum optimal, khususnya pada sistem Make to Order (MTO). Penelitian ini bertujuan untuk meningkatkan produktivitas UMKM konveksi melalui penerapan Lean Manufacturing. Pendekatan penelitian difokuskan pada identifikasi aktivitas yang tidak memberikan nilai tambah serta pengkajian terhadap berbagai bentuk pemborosan yang terjadi selama proses produksi. Berdasarkan hasil pengamatan, diperoleh tingkat defect sebesar 8% dari total produksi tahunan, yang mengindikasikan bahwa proses produksi masih belum efisien. Setelah dilakukan perbaikan melalui penataan alat kerja, penerapan line balancing, dan pengelompokan proses menjadi 4 stasiun kerja, terjadi peningkatan efisiensi yang signifikan. Total waktu produksi menurun menjadi 1635,76 detik (lebih cepat 49%), NVA berkurang menjadi 217,29 detik (turun 81,6%), serta waiting time berhasil dieliminasi menjadi 0 detik.
SIMULASI DENGAN PENDEKATAN METODE GREEN LEAN MANUFACTURING GUNA MENGEVALUASI PEMBOROSAN WAKTU PADA PT. ANS DENGAN SISTEM DINAMIS Naswa Salsabila; Ahmad; Andres
Jurnal Mitra Teknik Industri Vol. 4 No. 3 (2025): Jurnal Mitra Teknik Industri
Publisher : Universitas Tarumanagara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24912/a74c9c23

Abstract

This manufacturing company operates in the automotive industry with a Make to Order (MTO) production system, producing motorcycle engine components. Observations revealed production inefficiencies due to waste in the form of waiting time and excessive motion, leading to increased operational time and costs. This study aims to identify sources of waste, analyze root causes, and propose improvements using the Green Lean Manufacturing approach, which emphasizes both production efficiency and environmental considerations. The methods applied include Value Stream Mapping (VSM), Fishbone Diagram, 5 Why’s analysis, and system dynamics simulation. Based on the Current VSM analysis, the lead time was 268.21 minutes with a Process Cycle Efficiency (PCE) of 77.32%. Proposed improvements include relocating materials closer to machines, preparing tools before production, and adding workplace facilities. The Future VSM showed a lead time reduction of 17.92 minutes and a PCE increase of 1.17%. From the three simulated scenarios, ANOVA test results indicated that Scenario 3 was the most effective in reducing motion waste, while Scenario 2 best reduced waiting time. Both scenarios demonstrated the effectiveness of continuous lean implementation over a five-year period.
USULAN PERBAIKAN KUALITAS PRODUKSI LEM MENGGUNAKAN PENDEKATAN LEAN SIX SIGMA DAN POKA-YOKE DI PT LIGNO SPECIALITY ADHESIVE Whilly Abdullah Wicaksono; Ahmad; Carla Olyvia Doaly
Jurnal Mitra Teknik Industri Vol. 5 No. 2 (2026): Jurnal Mitra Teknik Industri
Publisher : Universitas Tarumanagara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24912/jmti.v5i2.39033

Abstract

Manufacturing companies in Indonesia consistently show dynamic development from year to year. PT Ligno Specialty, a manufacturing company, has issues in its production process that are causing an increase in defect rates. This research aims to reduce the defect rate of the LA 232 A adhesive product at PT Ligno Specialty Adhesive thru the application of the Lean Six Sigma method with the DMAIC framework and the design of Poka-Yoke mechanisms. Production data for the year 2025 shows a total defect of 5,970 kg out of 91,703 kg of production, with a DPU value of 0.0651, a DPMO of 16,275, and a sigma level of 3. These results indicate that the process quality is still at the industry average level. Root cause analysis shows the dominance of human error, such as material weighing mistakes and non-compliance with production flow. The proposed improvements include the implementation of the Poka-Yoke system at critical points in the process and Lean Six Sigma-based quality control. To reduce the defect rate, the research suggests improvements thru the Poka-Yoke approach. The proposed solutions include the addition of a flow meter on the water tap for measurement accuracy, the provision of a quarantine area for weighed materials to prevent mixing, and the implementation of a production check sheet that must be filled out by operators and supervised by a supervisor. It is expected to improve production yield and reduce the Cost of Poor Quality (COPQ).
Co-Authors Andres Doaly, Carla Olyvia Meirista Wulandari Naswa Salsabila Rio Saputra Whilly Abdullah Wicaksono