Implementasi Kaizen dan Prevention Poka-Yoke untuk Mengurangi Waste Kotor pada Transfer Conveyor Produksi Biskuit Di Industri Makanan Stix
DOI:
https://doi.org/10.31004/ijisk.v3i4.823Keywords:
Kaizen, Poka-Yoke, Transfer Conveyor, Waste Kotor, BiskuitAbstract
Penelitian ini mengkaji pengurangan waste kotor pada titik perpindahan biskuit antar conveyor di industri makanan Stix. Masalah utama berupa produk yang jatuh ke lantai pada area transfer conveyor dengan rata-rata waste kotor 10,17% selama Januari–Juni 2026, sedangkan batas perusahaan adalah 2,5% per bulan. Penelitian bertujuan mengidentifikasi akar penyebab, menerapkan perbaikan, dan mengukur efektivitasnya. Penelitian menggunakan pendekatan Kaizen melalui siklus Plan, Do, Check, Act yang dipadukan dengan prevention poka-yoke. Data diperoleh melalui observasi, wawancara, pengukuran, dokumentasi, dan data produksi. Analisis penyebab menggunakan fishbone diagram dan 5W1H. Hasil menunjukkan tiga akar penyebab utama, yaitu tidak adanya standar jarak gap antar conveyor, tidak adanya standar pemasangan guidance, dan belum tersedianya catch tray. Perbaikan dilakukan dengan mengurangi gap dari sekitar 35 mm menjadi 6–8 mm, meningkatkan tinggi guidance menjadi 44–46 mm, menutup celah sambungan, dan memasang 28 unit catch tray berbahan food grade. Waste kotor turun dari 423,45 kg (9,60%) pada Juli 2026 menjadi 121,80 kg (2,60%) pada September 2026. Efektivitas perbaikan mencapai 71,24% dan masuk kategori efektif. Temuan menunjukkan bahwa integrasi Kaizen dan poka-yoke dapat menekan kehilangan bahan baku pada titik transfer.
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