A potential inefficiency management: Kaizen application in the fillet processing of frozen demersal fish at PT. X Makassar-South Sulawesi

Abstract

PT. X is constantly lost profit allegedly due to inefficiencies in the processing of demersal fish fillets. This research was aimed to analyze the problem using the Kaizen method, a systematic analysis approach for continuous improvement. The research included the definition of the main problem, identification of the root causes on the employees, methods, materials and machine aspects, as well as identification of actions that are technically implementable and financially require less cost but produce maximum impact. The analysis of the production data in the frozen grouper fillets processing found differences in maximum yield in two production lines: 31.20% in Line 1 and 35.25% in Line 2, while the company's overall standard yield was 33%. These results indicated that interventions in Line 1 are needed to increase the yield by 2%. Root cause analysis found a numbery internal aspects that could be improved through Kaizen intervention, namely sorting raw materials, filleting, skinning, and trimming. Two interventions were recommended including employees training who in those aspects, and calibrating the main equipment. With such interventions, the inefficiencies worth Rp. 6.000,-/Kg of final product equivalent to Rp. 1.000.000.000,-/year of production could be overcome.