REDUCING SHIFTLY CLEANING PROCESSING TIME IN PACKAGING AREA AT CIGARETTE MANUFACTURING COMPANY, WEST JAVA

Abstract

Shiftly cleaning processing time in Packaging area of PT XY is high. Cleaning process is reason of machine should stop and reducing output which can be produced. In Packaging area of PT XY, there are two kinds of machine, which are Packer and Wrapper machine. Cleaning processing time in Packaging area are 1,968.75 seconds for Packer and 1,579.75 seconds for Wrapper. Therefore, in order to reduce cleaning time, concept of lean manufacturing is adopted. In Lean Manufacturing, non-value added activities is considering as waste, such as cleaning activities. FPC and Flow diagram are used for explaining cleaning process. Other Lean tools also used in order to make further improvements, which is 5S for having better tools arrangement for cleaning activity. Later, new cleaning process sequence is created to reduce time and operator’s motion. After making an analysis of the improvement, it was expected to reduce the shiftly cleaning time from 1,968.75 seconds to 884.37 seconds or by 44.92% for Packer machine. While, in Wrapper machine the reduction of shiftly cleaning processing time is from 1,579.75 seconds to 451.51 seconds or by 28.58%. Then the company will be able to save production loss by IDR 6,300,000,- for one day.