PENINGKATAN PRODUKTIVITAS PERUSAHAAN DENGAN MENGGUNAKAN METODE SIX SIGMA, LEAN DAN KAIZEN

Abstract

Improving productivity is the most important factors in the development of the company to seek profit. The process of improving productiviy can be done by reducing the activity of waste in the production process. Waste is non-value-added activities in the activity of the production process so that the inefficient use of working time. The purpose of this study is to reduce the activity of waste in the production process to improve productivity. The method used is the six sigma methodology which consists of define, measure, analyse, and improve. Define phase process that defines the problems that occur in the company and work activities. Measure phase process that calculates that standard time, calculate the initial productivity and make the current value stream mapping (CVSM). Analyse phase process is to analyse the causes of waste, and analyse the current value stream mapping (CVSM). Improve phase process that makes the proposed map of the operation, work activities, and plant layout to improve productivity, calculate the new productivity, and create future value stream mapping (FVSM). After that, create a standard operating procedure work culture with 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke). The results found early labour productivity series order of 1.56 sigma, after repair to 1.99 sigma. On the map of the current operation discovered the transport time = 37.5 min and a delay time = 305 minutes. On the map of the proposed operation resulting transport time = 16.25 minutes and the time delay = 70 minutes. In CVSM cycle time = 4.71 hours, and lead time = 38.86 hours with a total WIP = 299 units. At FVSM clock cycle time = 4.399, and the lead time = 30.01 hours with a total WIP = 198 units.