Efficiency Enhancement of Fried Shallot Production Cycle Time Through The Application of Lean Manufacturing Methodology

Abstract

The length of the cycle time is affected by the layout of the production room. It is known that CV Monita FOOD's production space arrangement has not adopted the layout principle perfectly when analyzed from the placement of its facilities. Discrepancies were found between layout principles which resulted in increased wastage of time during production. This waste fulfills up to 34% of the existing lead time thereby extending the cycle time and reducing the percentage of production efficiency. Waste can be minimized through the application of a strategy with a lean manufacturing approach. The aims of this research are 1) to analyze the efficiency level of the current layout, 2) to propose a layout with a lean approach, 3) to analyze the efficiency level of the proposed layout, and 4) to calculate the increase in income if the layout is adopted. Primary and secondary data collection was carried out using observation techniques, field documentation with stop watch time studies, interviews and literature studies. The data analysis tool used is the calculation of process cycle efficiency, activity relationship, BLOCKPLAN and production improvement. The results of this study are 1) the layout efficiency level is only 66%, 34% of fried onion production activities are non-value added so % 2) the new layout proposal is carried out with a lean approach using Activity Relationship raw data, 3) the new layout provides an increase in efficiency of up to 15%, and 4) This increase in efficiency can provide an increase in income of up to IDR 166,430,000 per month due to the additional output of
89kg/cycle. Calculation of the amount of increase in income in this study is calculated as a continuation of previous research with related topics because it has never been done before.