Waste Analysis in UD Tani Mulia With Lean Manufacturing Approach

Fahdhila, Dhila (2022) Waste Analysis in UD Tani Mulia With Lean Manufacturing Approach. Diploma thesis, Universitas Andalas.

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Abstract

The level of competition in business is getting more challenging. Every industry should have the ability to increase competitiveness. One of the keys that can support the industry's competitive ability is the quality of the entire production process. UD Tani Mulia is a food and beverage industry that produces noodles with the "Rumah Adat" brand. UD Tani Mulia is an Industry that has a high demand, but the Production is uncontrollable, has a long lead time, and its capacity is limited. Therefore, UD Tani Mulia can't fulfill all the customer needs. Based on the observation, the production process at UD Tani Mulia is still not optimal. Many activities do not add value, causing long production lead times. The percentage of value-added activities is 39%. Therefore, it is necessary to conduct a waste analysis to reduce lead time and increase company productivity. After analysis using the Waste Assessment Model, the three wastes that have the most influence on manufacturing lead time are waiting, inappropriate processing, and motion waste, with 23%, 18%, and 16%. The waste that occurs is then analyzed using a Fishbone diagram to find out the cause of the waste. The causes of wastage include the lack of material planning and control, uncontrollable drying process, limited drying container, downtime because of a power outage and breakdown machine, undisciplined workers, ineffective rolling and packaging processes, manual loading and unloading of materials activity, and a lot of idle time of drying operators. The recommendations for improvement proposed to reduce waste and increase productivity include pull-replenishment as the material planning and control, workplace organization, one-piece flow in the packaging process, rolling process improvement, and multipurpose dryer instead of the manual drying process. The proposed improvements can increase the proportion of value-added time. The current PCE is 39% and can increase to 93%.

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