The WASTE ANALYSIS IN THE PRODUCTION OF PACKAGED BEVERAGES WITH LEAN MANUFACTURING AND FMEA METHODS AT PT XYZ

Abstract

The packaged beverage industry is experiencing rapid growth in response to demand. This study aims to identify, analyze, and minimize various types of waste in the production process packaged beverages at PT XYZ using a Lean Manufacturing approach that integrates Value Stream Mapping (VSM), and Failure Mode and Effect Analysis (FMEA). Waste weighting analysis showed that unnecessary motion was the most critical waste with the highest weight of 4.71, followed by waiting with a weight of 4.14, overprocessing with a weight of 3.86, overproduction with a weight of 3.57, excessive motion with a weight of 2.86 and excess inventory with a weight of 2.57. Mapping the current state process using VSM succeeded in minimizing the initial lead time from 687 minutes to 568 minutes by reducing the process time. The implementation of improvement proposals that include the implementation of visual control with work standardization, as well as the integration of information systems and quality control resulted in an increase in Process Cycle Efficiency (PCE) from 25% to 30%. This study proves that the integration of Lean Manufacturing and improvement recommendations with FMEA is effective in reducing waste, shortening lead time, and improving the efficiency of the packaged beverage production process in a sustainable manner