Pengembangan 9 Waste Extended Value Stream Mapping untuk Mendukung Implementasi Lean Manufacturing
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Proses produksi pada industri manufaktur berat menghadapi pemborosan operasional sekaligus risiko kesehatan, keselamatan, dan lingkungan yang dapat menurunkan efisiensi proses. Value Stream Mapping (VSM) tradisional terutama merepresentasikan aliran material dan informasi sehingga masih terbatas dalam menggambarkan faktor manusia dan kondisi Health, Safety, and Environment (HSE). Penelitian ini mengembangkan 9 Waste Extended Value Stream Mapping (EVSM) dengan memperluas EVSM delapan waste dari penelitian terdahulu dan menambahkan HSE sebagai kategori waste kesembilan. Peta yang dikembangkan mengintegrasikan cycle time, waiting time, work in process, defect rate, aliran transportasi, risiko ergonomi menggunakan REBA, beban kerja mental menggunakan NASA-TLX, non-utilized talent, penilaian risiko HSE, serta pengukuran kondisi lingkungan kerja. Metode diaplikasikan pada tujuh proses pengecoran bogie di PT X, yaitu core making, mold making, setting core, melting, pouring, shakeout, dan shotblast. Hasil current state 9 Waste EVSM mengidentifikasi delapan dari sembilan kategori waste. Waiting menjadi waste yang paling sering ditemukan dengan 14 temuan, diikuti motion dan non-utilized talent masing-masing lima temuan, defect empat temuan, serta transportation, inventory, HSE, dan extra-processing masing-masing tiga temuan. Overproduction tidak ditemukan selama periode pengamatan. 9 Waste EVSM yang dikembangkan memberikan dasar visual yang lebih komprehensif untuk mendukung implementasi Lean Manufacturing karena menampilkan kondisi operasional, faktor manusia, kualitas, dan HSE pada setiap tahapan proses secara terintegrasi.
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