Waste Minimization Using Lean Manufacturing Method in PT Semen Padang

Angela, Artha Adventina Lubis (2016) Waste Minimization Using Lean Manufacturing Method in PT Semen Padang. Diploma thesis, Universitas Andalas.

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Abstract

Cement is one of the strategic commodities that supporting acceleration of infrastructure development and economic growth. Development of cement industry will result a positive effect to master plan of government. Increasing cement industry performance needs innovations of the production process to be more effective and efficient. In order to improve the production system, companies are required to understand what kind of activities can increase the value added on the product. A number of methods can be used as an innovative way to minimize the wastes in the cement production process. Waste identification and minimization is conducted by methods of Value Stream Mapping (VSM), Waste Relationship Matrix (WRM), Waste Assessment Questionnaire (WAQ), and Value Stream Analysis Tools (VALSAT). Next stages are identifying the root cause of problem, defining the risk potential number, and developing the action plans using Cause and Effect Diagram and Failure Mode and Effect Analysis (FMEA). Based on Value Stream Mapping, obtained the current production cycle time is 13,910.01 seconds. Current State Mapping shows the indication of wastes consist of defects, overproduction, and inventory through lost time value and storage time of inventory. Suggestions to minimize wastes in Future State Mapping are conducted by Heijunka method, Kanban, Kaizen, Andon, and Lean Supermarket. The results of Waste Identification using Waste Relationship Matrix (WRM) and Waste Assessment Questionnaire (WAQ), obtained the ranking of wastes where the three highest wastes are Defects (19.747%), Overproduction (19.043%), and Inventory (17.877%). Mapping tool selected by Value Stream Analysis Tools (VALSAT) is Process Activity Mapping (PAM) with mapping weight of 482,426. The results show 35% of Value Added activities, 60% of Non Value Added but Necessary activities and 5% of Non Value Added activities are include in the cement production processes of Indarung V Plant of PT Semen Padang. The waste identification results then used to develop the suggestions of minimizing wastes. Cause and Effect Diagram presents the root cause of three highest wastes based on categorizes of Man, Material, Machine, System, Marketing, Process, and Method. The root cause is used to understand the basic problem of wastes occured in the cement production processes. Failure Mode and Effect Analysis (FMEA) is conducted to 45 failure modes of the three main operations in the cement production. The results of the Risk Priority Number (RPN) obtained the highest score is Failure Modes in the Raw Mill operation with a value of 65.61. Low quality of material is the highest potential risk that needs urgent attention from production department in the Indarung V Plant of PT Semen Padang. The action plans for that potential risk is accomplished by Quality Control of material. Keywords: lean manufacturing, the cement production process, waste minimization

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