Pendekatan Lean Manufacturing dan Algoritma Craft Sebagai Upaya Peningkatan Efisiensi Produksi Tahu Saudara Jaya Jember (Studi Kasus: Produksi Tahu Saudara Jaya)

Abstract

This study aims to identify waste and improve production process efficiency at Saudara Jaya Jember tofu factory using Value Stream Mapping (VSM), Process Activity Mapping (PAM), DOWNTIME analysis and 5 Whys, as well as layout redesign using the CRAFT method. The results show that the production process consists of 10 stages and 21 activities with a total time of 2432,22 minutes, including 1962,60 minutes of value-added (VA) activities, 314.5 minutes of non value-added (NVA) activities, and 155.12 minutes of necessary but non-value added (NNVA) activities. VSM analysis showed a processing time of 2401,07 minutes, a lead time of 1978,15 minutes, and a takt time of 1.92 minutes/kg, with the longest times spent on grinding (29%), soaking (20%), and pressing (14%), as well as waiting times in the grinding, cooking, and tofu forming processes. The waste found includes defects, overproduction, waiting, non-utilized talent, transportation, inventory, and motion, with the furthest distance from pressing to cutting and packaging being 1833 m/day, movement time of 3967 seconds/day, and material handling costs of IDR 796,534/day. The proposed improvements, which included the implementation of SOPs, demand-based production planning, more efficient work distribution, workstation improvements, and layout redesign using CRAFT, as well as production process improvements, resulted in an increase in grinding capacity from 26.54 kg/hour to 40 kg/hour, a reduction in process time from 7.06 hours to 4.70 hours (31.05%), a reduction in soaking time from 8 hours to 1 hour (±75%), and a reduction in cutting time from 105.30 minutes to 71.50 minutes. Overall, lean improvements and layout changes have the potential to increase production flow efficiency and reduce waste.