Harnessing Lean and FMEA Techniques to Eliminate Waste and Enhance Performance in Poultry Processing
Memanfaatkan Teknik Lean dan FMEA untuk Menghilangkan Pemborosan dan Meningkatkan Kinerja dalam Pemrosesan Ayam Hidup
DOI:
https://doi.org/10.21070/ups.7066Keywords:
Lean Manufacturing, Production Process, Failure Mode And Effect Analysis (FMEA), Waste Reduction, Quality Improvement, Operational EfficiencyAbstract
This study aims to improve efficiency and reduce waste in the live chicken processing industry by applying the Lean Manufacturing method and Failure Mode and Effects Analysis (FMEA). The Lean method was used to identify seven main types of waste, including transportation, inventory, movement, waiting, over-processing, over-production, and defects. Meanwhile, FMEA was applied to prioritize corrective actions based on the highest Risk Priority Number (RPN), which is calculated from severity, frequency of occurrence, and detection. The results showed that after the implementation of Lean and FMEA, there was a significant decrease in labor costs, operating costs, and raw material wastage ratio. Labor costs were reduced by 5.8%, operational costs dropped by 2.3%, and raw material wastage decreased by 1.2%. These decreases reflect increased efficiency in resource utilization and a reduction in non-value-added activities. The conclusion of this study shows that the combination of Lean Manufacturing and FMEA provides an effective solution to overcome waste and improve performance in the production process of the live chicken processing industry. The application of this method is potentially a model that can be adopted by similar industries to streamline operations and improve efficiency.
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