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EFFECTIVE IMPLEMENTATION OF LEAN MANUFACTURING IN PT KALBE FARMA TBK

Master Theses from JBPTITBPP / 2014-02-06 09:30:56
Oleh : PRASTI SULANJARI , S2 - Business Administration
Dibuat : 2014-01-27, dengan 6 file

Keyword : Lean Manufacturing, Lead Time, WIP, Achievement Rate, Total Productive Maintenance

PT Kalbe Farma Tbk is one of the largest pharmaceutical company in Southeast Asia. PT Kalbe Farma Tbk is capable of producing superior quality products in local and international markets. Products and services that are owned PT Kalbe Farma Tbk is divided into four categories of prescription drugs, health products, nutritional products and distribution. PT Kalbe Farma Tbk concerns of two financial measures which are the gross margin and operating profit margin. Both of these financial measures are quite low due to high production cost component. Production costs are influenced by the high average value of inventory. Inventory which meant here are the inventory of materials, semi-finished materials inventory and finished product inventory. To cope with the amount of inventory that is high enough, PT Kalbe Farma Tbk implement lean manufacturing in order to obtain the production process that uses the minimum inventory Programs lean manufacturing called Kalbe Lean System which goals are lower lead time, higher quality and low cost. The purpose of this study was to determine the effectiveness of the implementation of lean manufacturing in PT Kalbe Farma Tbk and its impact. The study uses secondary data methodology which are lead time, the amount of work in process (WIP) and achievement rate. The study focused on the production process flow Promag on Line 1. Determination of the target lead time and the amount of inventory is divided into three periods. In the first and second period, lead time and the amount of inventory is slowly lowered to be determined at 1 day and 7 batch. In the second period, the achievement of production fell by an average of 63.44%. Then in the third period, lead time and WIP amount was increased to 2.5 days and 17 batches so that the achievement of the average production per month was increased to 94.93%. For three times the period of the determination of lead time and the amount of WIP, obtained trend that the lower lead time and WIP, the lower the amount of achievement rate. After analysis in the period from September to November 2010 related to achievement rate decline is line stop was quite high. One cause that is dominant is the absence of a tablet and after visible roots of the problem is caused by unplanned breakdown. With the applied flow, part of the lean, so if there is one machine breaks down then the next machine canÂ’t run because of the amount of WIP is set as low as possible. Appropriate to principles of Toyota Production System and Operational Excellence, the basis of the application of lean manufacturing is a system of production, including production machinery, need to be stable. According to Liker, when enginee often stops, management needs to think to implement Total Productive Maintenance (TPM). TPM involves all employees of all levels to maintain engine performance.

Deskripsi Alternatif :

PT Kalbe Farma Tbk merupakan salah satu perusahaan farmasi terbesar di Asia Tenggara. PT Kalbe Farma Tbk mampu menghasilkan produk superior yang berkualitas di pasar lokal dan internasional. Produk dan service yang dimiliki PT Kalbe Farma Tbk terbagi menjadi 4 kategori yaitu obat resep, produk kesehatan, produk nutrisi dan distribusi. Pengukuranfinansial yang menjadi perhatian PT Kalbe Farma Tbk adalah marjin laba kotor dan marjin keuntungan operasi. Kedua pengukuran finansial tersebut diperoleh cukup rendah dikarenakan komponen biaya produksi yang tinggi. Biaya produksi dipengaruhi oleh tingginya nilai inventory rata-rata. Inventory yang dimaksud disini adalah inventory material, inventory bahan setengah jadi dan inventory produk jadi. Untuk mengatasi jumlah inventory yang cukup tinggi, PT Kalbe Farma Tbk menerapkan lean manufacturing sehingga diperoleh proses produksi yang menggunakan inventory seminimal mungkin. Program lean manufacturing yang dijalankan dinamakan Kalbe Lean System dengan tujuan lead time pendek, kualitas tinggi dan dengan biaya rendah. Tujuan penelitian ini adalah mengetahui efektifitas implementasi lean manufacturing di PT Kalbe Farma Tbk dan dampaknya. Penelitian menggunakan metodologi data sekunder berupa lead time, jumlah inventory dan pencapaian produksi. Penelitian difokuskan pada alur proses produksi Promag di Line 1. Penentuan target lead time dan jumlah inventory dibagi menjadi tiga periode. Pada periode kesatu dan kedua, lead time dan jumlah inventory secara perlahanditurunkan sampai ditentukan sebesar 1 hari dan 7 batch. Pada kedua periode tersebut, pencapaian produksi turun hingga mencapai rata-rata 63,44%. Maka pada periode ketiga, lead time dan jumlah WIP ditingkatkan menjadi 2,5 hari dan 17 batch sehingga pencapaian produksi rata-rata per bulan pun meningkat menjadi 94,93%. Selama tiga kali periode penentuan lead time dan jumlah inventory, diperoleh trend bahwa semakin rendah lead time dan jumlah inventory maka semakin rendah pencapaian produksi. Setelah dilakukan analisa pada periode Sep-Nov 2010 terkait turunnya pencapaian produksi adalah cukup tingginya line stop atau terhentinya produksi. Salah satu penyebab yang cukup dominan adalah tidak adanya tablet dan setelah dilihat akar masalahnya disebabkan oleh unplanned breakdown. Dengan diterapkan proses mengalir, bagian dari lean, maka apabila ada salah satu mesin rusak maka mesin berikutnya tidak bisa berjalan karena jumlah inventory ditetapkan serendah mungkin. Sesuai prinsip Toyota Production System dan Operational Excellence, dasar dari penerapan lean manufacturing adalah sistem produksi, termasuk mesin produksi, yang stabil. Menurut Liker, apabila mesin sering berhenti maka manajemen perlu berpikir untuk menerapkan Total Productive Maintenance (TPM). TPM melibatkan seluruh karyawan dari semua level untuk menjaga kinerja mesin.

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