Ayu Puspita Astika
041324353014                                                                                                                                             Dosen Pembimbing                                                                                                                             Prof.Ir.Suparno, MSIE.,Ph.D  

ABSTRACT

Due to the fierce competition nowadays, a company is demanded to have competitive advantage in both regional and global level. One of companies that is in the loop of global competition is PT. XYZ. PT. XYZ is multinational pharmaceutical company in Indonesia. Currently, PT. XYZ strives to achieve the vision “Highest Quality, Lowest Cost, and Shortest Lead Time”

The purpose of this research is to explore the reduction of waste in the end-to-end process for packaging facility in department IPT B that leads to the late of shipment. Waste reduction chosen because PT. XYZ truly focuses in customer and expect that the pharmaceutical product delivered on time. This research method used is qualitative explanatory approach to disclose the problem that occur and how to propose problem solving on it.
In accordance on the data processing, the result of this research was the highest waste due to the longest lead time. Based on analysis using values stream mapping, fishbone diagram confirmed that the process with the longest lead time was proses of packaging component inspection, process quality release, and shipment process. By referring to the man, machine, method, material, and environment, the most contributing factor for those three processes based on man, machine, method, and material factor
Therefore, improvement activities were proposed by using Failure Mode and Effect Analysis (FMEA) to know the order and the risk. Based on FMEA result, the main proposed improvement for packaging component inspection was vendor qualification. Meanwhile for Quality release process, the improvement activity proposed was kaizen activity to fix all master data, install Total Preventive maintenance (TPM. Lastly, for shipment process the main proposed improvement activity was visualize document accuracy in tier outbound board and socialize and train on Kanban due to shortage of pick & pack covering material. Based on the improvement above lead time can decrease from 106 days in total into 92 days by giving some adjustment and so that it can increase the shipment accuracy
Keywords: waste, values stream mapping, lead time, fishbone diagram, FMEA