WASTE MINIMIZATION IN PACKING BAG PRODUCTION PROCESS IN PACKING BAG PLANT OF PT. SEMEN PADANG

Mutty, Oktaviani (2020) WASTE MINIMIZATION IN PACKING BAG PRODUCTION PROCESS IN PACKING BAG PLANT OF PT. SEMEN PADANG. Diploma thesis, Universitas Andalas.

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Abstract

The competition in the manufacturing industry sector requires every company to do continues improvements and develop its performance. One of the competitive manufacturing industries is cement industry. PT. Semen Padang is cement company located in Padang that produces seven types of cement that use two types of packing bags which are pasted bag and sewing bag. Packing bag plant unit of PT. Semen Padang has an important role to produce the pasted bag. In order to enhance productivity and improve product quality, the company has to know which activity increases value-added-activity to the product. There are some methods can be used to minimize the wastes in packing bag production process. Waste identification began with the identification of Current State Value Stream Mapping with weighting the waste by using Waste Relationship Matrix and Waste Assessment Questionnaire in order to understand the root of the problem within the production process. Based on the WRM and WAQ result, the most dominant wastes are defect (24,4%), inventory (16,3%) and waiting waste (15,2%). The detail mapping selection was using Value Stream Analysis Tools (VALSAT) with Process Activity Mapping (PAM) as the selected tool. It is obtained 42 activities in production line III with 9,6% non-value-added activities and 43 activities in production line IV with 9,3% non-value-added activities. Fishbone diagram is used to analyse the root cause to understand the root of problem for production process and followed by FMEA with 33 potential failures is found. The highest score of Risk Priority Number (RPN) is the potential failure because of defect waste which is unavailability of spare parts with RPN of 172,8. Proposed recommendations are given to minimize the existing waste and prevent waste in the future by applying Lean Manufacturing concept. Keywords: Cement Packing Bag, Fishbone Diagram, FMEA, Lean Manufacturing, Waste Minimization

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