Analisis Penyebab Waste pada Proses Pengantongan Pupuk dengan Metode Lean Six Sigma dan 5 Whys di Gudang PT XYZ
Abstract
Industri pupuk perlu menjaga kualitas produk dan meningkatkan efisiensi proses produksi agar mampu memenuhi kebutuhan pasar serta mempertahankan daya saing. Pada proses pengantongan pupuk masih ditemukan aktivitas tidak bernilai tambah yang menyebabkan produk cacat. Selama 6 bulan, total produksi mencapai 211.770 ton dengan cacat sebesar 16.506 ton. Penelitian ini bertujuan mengidentifikasi pemborosan dominan, menganalisis akar penyebab, dan menyusun usulan perbaikan. Metode yang digunakan adalah Lean Six Sigma dengan tahapan DMAIC serta alat analisis Value Stream Mapping, Process Activity Mapping, Value Stream Analysis Tools, Diagram Pareto, Diagram Fishbone, dan 5 Whys. Hasil menunjukkan DPMO sebesar 19.436, nilai sigma 3,57, dan kapabilitas proses 1,19. Pemborosan dominan meliputi defect, waiting, dan motion dengan PCE awal 52,5%. Usulan perbaikan meliputi inspeksi dan kalibrasi timbangan, check sheet monitoring, guide plate pada sewing machine, serta pengelolaan forklift, dengan peningkatan PCE menjadi 64,3%.
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