Combination of Value Stream Mapping and House of Risk Methods to Eliminate Waste in Productivity Enhancement in Production Area of Fertilizer Company

Abstract

Success in ensuring agricultural production through fertilizer production is the key to strengthening national food security. PT X is a domestic company producing ZA fertilizer. In this study, the endeavor to implement lean manufacturing with a nine wastes (E-DOWNTIME) approach to eliminate waste, so productivity can be increased by relying on a combination of VSM and HOR methods to identify wastes to propose remedies to the risks arising from waste on the ZA production floor, through FGD. This research focuses on risks to waste each production process flow according to the business process adopted. The results showed a waste of waiting, defects, excess processing, and EHS on the ZA production floor. 28 risk events were identified and 28 risk agents were identified. After two alternative repairs were selected namely replacement of the drum filter shaft and replacement of the turbine rotor, the duration of the NVA was 79 minutes reduced. Corrosion, aging, and abrasion machines/tools are the selected risk agents, representing that operating machines have shown a decline in performance due to age, so that a gradual machine update is necessary.