Identifikasi Waste pada Proses Produksi UKM Kain Jumputan dengan Pendekatan Value Stream Mapping dan Failure Mode and Effect Analysis
DOI:
https://doi.org/10.32502/integrasi.v10i1.624Keywords:
FMEA, Value Stream Mapping, pemborosan produksi, UKMAbstract
UKM Kain Jumputan sebagai pengrajin tie-dye menghadapi berbagai bentuk pemborosan dalam proses produksinya, seperti waktu tunggu, pergerakan yang tidak efisien, dan produk cacat. Penelitian ini bertujuan untuk mengidentifikasi jenis pemborosan dalam proses produksi menggunakan pendekatan Value Stream Mapping (VSM) dan menganalisis penyebab kegagalan menggunakan metode Failure Mode and Effect Analysis (FMEA). Kebaruan dari penelitian ini terletak pada integrasi kedua metode tersebut dalam konteks industri kain tradisional skala kecil, serta penggunaan Waste Relationship Matrix (WRM) untuk memetakan keterkaitan antar waste secara kuantitatif. Hasil pemetaan menunjukkan bahwa dari total waktu proses 3961 menit, hanya 3484 menit (88%) yang merupakan aktivitas bernilai tambah. Pemborosan terbesar terdapat pada kategori defect (19%), motion (17%), serta inventory dan waiting (masing-masing 15%). Implikasi dari penelitian ini menunjukkan bahwa pendekatan integrasi VSM-FMEA dapat dijadikan alat strategis dalam mengindentifikasi dan memitigasi pemborosan secara menyeluruh pada sektor UKM kerajinan tradisional. Temuan ini relevan dengan tren global lean manufacturing dan mempunyai potensi untuk diaplikasikan pada berbagai industri serupa untuk mendorong efisiensi operasional.
References
H. Hatif, K. L. Lee, and G. Nawanir, “Improving Employee and Workplace Performance via Lean Manufacturing Practices: A Case Study in Textile Company,” Int. J. Ind. Manag., vol. 18, no. 1, pp. 43–59, 2024.
A. Pacana and K. Czerwińska, “Analysis of the Use of Agile Methods, Tools and Techniques in Foundry Enterprises,” Syst. Saf. Hum. - Tech. Facil. - Environ., vol. 5, no. 1, pp. 1–9, 2023.
M. Y. Anshori and D. F. Karya, “A Analysis of Factors Affecting Waste Using Value Stream Mapping (VSM) on Kaosbekas.Id,” J. Entrep. Dan Entrep., vol. 11, no. 2, pp. 139–154, 2022.
A. Szczyrba and M. Ingaldi, “Implementation of the Fmea Method As a Support for the Haccp System in the Polish Food Industry,” Manag. Syst. Prod. Eng., vol. 32, no. 3, pp. 357–371, 2024.
Siti Salimah Jalal, Suaniza Mamat, Zamzulalila Zakaria, and Mohamad Hafiz Rosli, “A Case Study on the Implementation of Lean Six Sigma in Malaysia Plantation Company,” Malaysian J. Bus. Econ., vol. 9, no. 1, pp. 65–81, 2022.
A. F. O. Pertiwi and R. D. Astuti, “Increased Line Efficiency by Improved Work Methods With the ECRS Concept in a Washing Machine Production: A Case Study,” J. Sist. Dan Manaj. Ind., vol. 4, no. 1, pp. 13–29, 2020.
G. Citybabu and S. Yamini, “Lean Six Sigma 4.0 – A Framework and Review for Lean Six Sigma Practices in the Digital Era,” Benchmarking an Int. J., vol. 31, no. 9, pp. 3288–3326, 2023.
M. A. S. Anuar and M. A. Mansor, “Application of Value Stream Mapping in the Automotive Industry: A Case Study,” J. Mod. Manuf. Syst. Technol., vol. 6, no. 2, pp. 34–41, 2022.
M. F. S. Titu, A. Chowdhury, S. M. R. Haque, and R. Khan, “Deep-Learning-Based Real-Time Visual Pollution Detection in Urban and Textile Environments,” Sci, vol. 6, no. 1, p. 5, 2024.
M. Braglia, M. Gallo, L. Marrazzini, and L. C. Santillo, “Operational Space Efficiency (OpSE): A Structured Metric to Evaluate the Efficient Use of Space in Industrial Workstations,” Int. J. Product. Perform. Manag., vol. 73, no. 4, pp. 1027–1049, 2023.
N. Kumar and S. Saini, “Some Recent Stories of Operational Excellence in SMES,” Int. J. Res. Appl. Sci. Eng. Technol., vol. 11, no. 12, pp. 1538–1551, 2023.
A. Patil, M. V Pisal, and C. T. Suryavanshi, “Application of Value Stream Mapping to Enhance Productivity by Reducing Manufacturing Lead Time in a Manufacturing Company: A Case Study,” J. Appl. Res. Technol., vol. 19, no. 1, pp. 11–22, 2021.
Q. Liu and H. Yang, “An Improved Value Stream Mapping to Prioritize Lean Optimization Scenarios Using Simulation and Multiple-Attribute Decision-Making Method,” Ieee Access, vol. 8, pp. 204914–204930, 2020.
I. Imtinan and B. Cahyaputri, “Waste Identification Using the Value Stream Mapping (VSM) Method on the PT XYZ Transparent Bar Soap Production Line,” J. Teknol. Dan Manaj., vol. 22, no. 1, pp. 27–34, 2024.
K. Knop and R. Ulewicz, “Solving Critical Quality Problems by Detecting and Eliminating their Root Causes – Case-Study from the Automotive Industry,” Mater. Res. Proc., vol. 24, pp. 181–188, 2022.
M. H. Ali, S. Zailani, M. Iranmanesh, and B. Foroughi, “Impacts of environmental factors on waste, energy, and resource management and sustainable performance,” Sustainability, 2019.
I. Elemure, H. N. Dhakal, M. Leseure, and J. Radulović, “Integration of Lean Green and Sustainability in Manufacturing: A Review on Current State and Future Perspectives,” Sustainability, vol. 15, no. 13, p. 10261, 2023.
S. M. Zahraee, A. Tolooie, S. J. Abrishami, N. Shiwakoti, and P. Stasinopoulos, “Lean manufacturing analysis of a Heater industry based on value stream mapping and computer simulation,” Procedia Manuf., vol. 51, no. 2019, pp. 1379–1386, 2020.
S. Silva, J. C. Sá, F. J. G. Silva, L. P. Ferreira, and G. Santos, “Lean Green—The Importance of Integrating Environment into Lean Philosophy—A Case Study,” 6th European Lean Educator Conference, ELEC 2019, vol. 122. Springer, ISEP—School of Engineering, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 431, Porto, 4200-072, Portugal, pp. 211–219, 2020.
M. B. Purushothaman, J. Seadon, and D. Moore, “A Relationship Between Bias, Lean Tools, and Waste,” Int. J. Lean Six Sigma, vol. 13, no. 4, pp. 897–936, 2021.
M. K. Onifade and O. A. Oroye, “Application of Lean Manufacturing Technology in a Milk Manufacturing Company,” J. Sist. Dan Manaj. Ind., vol. 5, no. 2, pp. 87–97, 2021.
I. Siddique, “Lean Manufacturing Excellence: Innovative Approaches in Industrial Engineering,” SSRN Electron. J., 2024.
S. Bagal and H. Dasgupta, “Factors Effective for Implementation of Lean in Manufacturing Organizations of India,” Cm, no. 24, pp. 510–516, 2022.
S.-V. Buer, M. Semini, J. O. Strandhagen, and F. Sgarbossa, “The Complementary Effect of Lean Manufacturing and Digitalisation on Operational Performance,” Int. J. Prod. Res., vol. 59, no. 7, pp. 1976–1992, 2020.
Ł. Hadaś and N. Pawlak, “Support for the Implementation of the Lean Concept by Industry 4.0 Tools – Experts’ Opinion,” Eur. Res. Stud. J., vol. XXIV, no. Special Issue 5, pp. 572–584, 2021.
J. J. C. Mancera, R. González, Á. M. Rodríguez-Pérez, and J. A. H. Torres, “MODELING AND SIMULATION OF INDUSTRIAL PROCESSES = Modelado Y Simulación De Procesos Industriales,” Adv. Build. Educ., vol. 8, no. 1, pp. 46–60, 2024.
A. Mortada and A. Soulhi, “Improvement of Assembly Line Efficiency by Using Lean Manufacturing Tools and Line Balancing Techniques,” Adv. Sci. Technol. – Res. J., vol. 17, no. 4, pp. 89–109, 2023.
A. Florescu and S. Barabas, “Development Trends of Production Systems Through the Integration of Lean Management and Industry 4.0,” Appl. Sci., vol. 12, no. 10, p. 4885, 2022.
M. Kanan et al., “An Empirical Study of the Implementation of an Integrated Ergo-Green-Lean Framework: A Case Study,” Sustainability, vol. 15, no. 13, p. 10138, 2023.
Y. Ali, A. Younus, A. U. Khan, and H. Pervez, “Impact of Lean, Six Sigma and Environmental Sustainability on the Performance of SMEs,” Int. J. Product. Perform. Manag., vol. 70, no. 8, pp. 2294–2318, 2020.
S. M. Widodo, R. D. Astanti, T. J. Ai, and T. M. A. A. Samadhi, “Seven-waste framework of waste identification and elimination for computer-based administrative work,” TQM J., vol. 33, no. 4, pp. 773–803, 2020.
I. A. Rawabdeh, “A model for the assessment of waste in job shop environments,” Int. J. Oper. Prod. Manag., vol. 25, no. 8, pp. 800–822, 2005.
Downloads
Additional Files
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Integrasi: Jurnal Ilmiah Teknik Industri
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
