ANALYSIS OF REDUCING WASTE AT LINE PRODUCTION OF AUTO ROOTING AREA AT TIY MANUFACTURING USING 5S METHOD

Abstract

PT MI toy manufacturing has a production place specifically for sewing doll hair called FAR (Full Auto Rooting). The FAR production area having a total of 319 sewing machines operating. The core issue in PT MI's FAR production area is the inadequate handling of generated waste, leading to potential work accidents. Analysis of waste data from May to July 2022 reveals significant quantities of yarn waste, reject sculpt, reject onyx, and feeddog scrap. This accumulation not only compromises workplace cleanliness but also contributes to safety hazards. To address these challenges, a 5S Checklist audit was conducted, resulting in a score of 53 out of 100, highlighting areas needing improvement. The proposed solution involves implementing Standard Operating Procedures (SOPs) aligned with 5S principles (Sort, Set in Order, Shine, Standardize, Sustain). These SOPs aim to enhance waste reduction practices, establish organizational standards, and promote a safer and more efficient working environment in the FAR production area. By integrating systematic sorting, organizing, cleaning, standardizing, and sustaining practices, PT MI seeks to mitigate waste-related risks and foster a culture of continuous improvement and safety awareness among its workforce.