Penerapan Lean Manufacturing pada Lini Produksi Hinge AFT dan Hinge FWD - Ahmad Hidayat Naqsabandi; Nita P. A. Hidayat; Chaznin R. Muhammad (UPT Publikasi Ilmiah Unisba, 2025)
Abstrak. PT. Dirgantara Indonesia (PT. DI) merupakan perusahaan manufaktur yang memproduksi pesawat terbang pertama di Indonesia dan menerapkan strategi produksi Engineering to Order (ETO) serta Make to Order (MTO) dalam merespons kebutuhan pasar. Berdasarkan hasil observasi, ditemukan beberapa aktivitas yang menimbulkan pemborosan (waste), yaitu defect, transportation, dan waiting time, yang berdampak pada lamanya waktu penyelesaian produk. Untuk mengurangi pemborosan tersebut, penelitian ini menggunakan pendekatan Lean Manufacturing. Alat analisis yang digunakan meliputi Diagram SIPOC, Value Stream Mapping (VSM), Diagram Pareto, Diagram Sebab Akibat, Failure Mode and Effect Analysis (FMEA), serta Kuesioner 7 Waste. Hasil identifikasi menunjukkan empat jenis pemborosan tertinggi, yaitu defect, transportation, waiting time, dan motion. Faktor penyebab pemborosan dianalisis menggunakan Diagram Sebab Akibat dan dijadikan dasar perhitungan Risk Priority Number (RPN) melalui FMEA. Usulan perbaikan meliputi perancangan maintenance checklist, standarisasi kerja visual menggunakan form monitoring, penambahan reach truck, serta perancangan ulang layout produksi. Implementasi perbaikan menurunkan production lead time dan meningkatkan nilai Process Cycle Efficiency (PCE). Abstract. PT. Dirgantara Indonesia (PT. DI) is a manufacturing company that produces the first aircraft in Indonesia and implements Engineering to Order (ETO) and Make to Order (MTO) production strategies to respond to market demands. Based on observations, several activities were identified as sources of waste, namely defect, transportation, and waiting time, which contribute to longer product completion times. To reduce these wastes, this study applies the Lean Manufacturing approach. The analytical tools used include the SIPOC Diagram, Value Stream Mapping (VSM), Pareto Diagram, Cause and Effect Diagram, Failure Mode and Effect Analysis (FMEA), and the 7 Waste Questionnaire. The results indicate four dominant types of waste: defect, transportation, waiting time, and motion. The causes of these wastes were analyzed using the Cause and Effect Diagram and served as the basis for calculating the Risk Priority Number (RPN) through FMEA. Improvement proposals include designing a maintenance checklist, visual work standardization using a monitoring form, adding a reach truck, and redesigning the production layout. The implementation of these improvements reduced production lead time and increased Process Cycle Efficiency (PCE).