IMPLEMENTATION OF LEAN AND GREEN MANUFACTURING CONCEPTS TO MINIMIZE WASTES AT PT IGASAR

The rapid development of industrial world has led the fierce competition among companies. The effort that can be made by the company to stay in competition is to improve the company's performances continuously. These performances measures are in term of four dimensions of company's goals which are customer satisfaction, benefits for stakeholders, the dignity of the employee, and benefits for the environment. In order to reach the target dimensions, each company strives to be effective and efficient. If there are still Non-Value Added (NVA) activities in the company, it can be said that the company has not run effectively. NVA activity also can be considered as waste. Waste must be eliminated in the Lean concept in order to add value to the manufacturing system, which in term will increase the overall performances. The seven wastes that must be eliminated are transportation, excess inventory, motion, waiting, overproduction, unnecessary processes, and defects. Wastes also have impacts on the environment. Applying the Lean and Green Manufacturing concepts to minimize wastes are also necessary for the environment. PT Igasar is a company engaged in concrete production. Based on the preliminary survey in the production area of PT Igasar and literature study, it was found that there are still wastes that must be eliminated. Therefore, it needs to improve the manufacturing system in PT Igasar by implementing Lean and Green Manufacturing concepts. System improvement is done by using the DMAIC methodology (Define, Measure, Analyze, Improve, and Control). Each stage is carried out using the appropriate tools, such as Current State Mapping, Waste Assessment Model (WAM), Basic Environmental Measures, Cause and Effect Diagram, and Failure Mode and Effect Analysis (FMEA). Based on WAM result, it is obtained the rank of wastes from the highest score to the smallest score, i.e.: Motion, Inventory, Overproduction, Defect, Waiting, Over-processing, and Transportation. The result of FMEA shows broken pulley is failure with the highest RPN value. So that, this failure needs more attention than others to decrease the potential risks. At the end, recommendation is given to overcome the existing wastes and prevent the waste in the future by applying Lean concept. The recommendations contain improve and controlling suggestion. Keywords: Cause and Effect Diagram, DMAIC, FMEA, Green Manufacturing, Lean Manufacturing, Wast