ANALISIS PEMBOROSAN PADA LANTAI PRODUKSI DENGAN METODE LEAN MANUFACTURING DI PT. GUNAWAN DIANJAYA STEEL Tbk. SURABAYA

In maintaining the existence of many ways companies used by a company for the results of his efforts remain in demand by consumers. The desire of consumers or the socalled voice of customer is very complex to make consumer companies should give priority above anything else, it aims to keep consumers loyal to the product. PT. Steel (GDS) is one of the major companies producing steel plate in Indonesia to international standard. The company is always improving product quality and continually trying to meet customer desires. But in the process of steel plate production of ABS type-A (12x1524x6096) mm, there are still obstacles to be faced. Of the many factors faced by these companies to make the course less so maximum production. As an example of waste found on the production floor so that the resulting losses to the company. In this study, researchers tried to analyze the activities that are categorized as non-value added. Therefore we need a method to identify the waste as a whole by using Lean Manufacturing through a VSM (Value Stream Mapping) Tools, where toolnya own election using VALSAT (Value Stream Analysis Tools) in hopes of reducing waste is happening. Based on research result shows that the manufacture of BPM (Big Picture Mapping), type of waste is successfully identified with BPM is Waiting, Unnecessary Inventory, and Overproduction. Besides it also can use the RCA (Root Cause Analysis) to identify waste, other waste. To minimize the waste that has been identified is given some proposed improvements, such as changing the company policy in preparation for cutting slab, to reduce waiting in preparation for cutting slab area of 10,080 minutes (7 days) to 420 minutes (0.29 days), change company policy in the process of cutting slabs, can reduce the waiting in the area of cutting the slab of 4752 minutes (3.3 days) to 272 minutes (0.19 days) and reduce overproduction of the 594 pieces to 34 pieces of slab slab, while also reducing unnecessary inventory of 17.5 days to 1.9 days. And after due analysis of the results of the proposed improvements may reduce significantly the production leadtime that initially 14 952 minutes (10.39 days) to 812 minutes (0.56 days)