Lean Manufacturing Implementation in Indonesian Coffee Processor


Sony Suwasono, Shinta Syafrina Endah Hapsari, Ida Bagus Suryaningrat, Djoko Soemarno


Abstract


The rapid competition between business and sustainability policy has encouraged the coffee industry in Indonesia to make their business more environmentally friendly. However, this initiative has yet to be fully underway. Several inefficiencies still prevail in Arabica coffee production sites, such as product defects in inventory, the inefficiency of production machine performance, and dependence on manpower that can increase the production and inventory costs. Therefore, the Arabica coffee agroindustry needs to improve its performance by addressing these issues in production activity using the lean manufacturing approach. Several tools proven influential to reduce waste in the agroindustry are Value Stream Mapping (VSM) and VALSAT. VSM could document the entire mapping of material and information management, but cannot classify the time required to complete the whole process. VALSAT has several derivative tools, but polyacrylamide (PAM) and Supply Chain Response Matrix (SCRM) are mostly used in agroindustry to classify value-added time of processes and illustrate the supply chain cumulative inventory of a company. The result of this study shows that the Indonesian Arabica coffee industry could reduce its cycle time by 57%, lead time by 63%, and changeover time by 50%. In addition, the recommendations result in the involvement of only 2 people during the drying process and eliminate the non-value-added time, while improving the overall production efficiency and capacity.

Full Text:

PDF

References


Hines, Peter and Rich, N, The Seven Value Stream Mapping Tools, International Journal of Operation and Production Management, Vol. 17 No. 1, 1997, pp. 46-64.

Goriwondo, Mhlanga, and Marecha, Use of Stream Mapping Tool for Waste Reduction in Manufacturing Case Study for Bread Manufacturing in Zimbabwe, International Conference on Industrial Engineering and Operations Management, 2011, pp. 236-241.

Prasetyo and Wicaksono, Desain Perbaikan untuk Meningkatkan Nilai Efisiensi Manufaktur Keberlanjutan menggunakan Sustainable Value Stream Mapping (Studi Kasus: CV Mugiharjo), 2019, Industrial Engineering Online Journal, Vol. 7 No. 4, pp. 1–7.

Ahmad, F and Aditya, D., Minimizing Waste with a Value Stream Mapping Approach, Journal of Industrial Systems Optimization, Vol. 18 No. 2, 2019, pp. 107-115.

Tarapituxwong, Tantranon, dan Duangpatra, Production Process Improvement Using Value Stream Mapping: A Case Study of Organic Coffee Firms in Thailand, Journal FEU Academic Review, Vol. 8 No. 2, 2015, pp 128-143.

Rimawan, Molle, and Putra, Lean Production Design with Waste and Method Analysis of VALSAT for Assembly Process of Four Wheel Vehicle Components, International Journal of Innovative Science and Research Technology, Vol. 11 No. 3, 2018, pp. 449-455.

Mor, Singh, and Bhardwaj, Learning on Lean Production: A Review of Opinion and Research within Environmental Constraints, Operations and Supply Chain Management, Vol. 9 No. 1, 2016, pp. 61-72.

Nordin, Deros, and Wahab, Lean Manufacturing Implementation in Malaysian Automotive Industry: An Exploratory Study, Operations and Supply Chain Management, Vol. 4 No. 1, 2011, pp. 21-30.

Lute and Charkha, Review of Lean Manufacturing Implementation: Case of Junction Box Post Processing Phase, International Journal of Civil, Mechanical and Energy Science, Special Issue 1, 2017, pp. 22-27.

Satria and Yuliawati, Perancangan Lean Manufacturing menggunakan Waste Assessment Model dan VALSAT untuk Meminimumkan Waste, Jurnal Rekayasa Sistem Industri, Vol. 7 No. 1, 2018, pp. 55-63.

Bhose, Pooja, Sulanke, and Hermant, Value Stream Mapping: Case Study on Residental Construction Sector, International Journal of Engineering Sciences Research Technology, 2015, pp. 353-360.

Kengar, Kadam, Pandit, and Vingale, Manufacturing System Performance Improvement by Value Stream Mapping a Literature Review, IJIRSET, Vol. 2 Issue 9, 2013, pp. 12709-12716.

Auliandri and Alfiani, Lean Manufacturing Approach to Reduce Wastefulness During Production of Train Car-Body Using VALSAT Method, Knowledge E, 2018, pp. 1256-1269.

Hidayat, Tama, and Efranto, Lean Manufacturing Approach with VSM and FMEA Methods to Reduce Waste in Plywood Products, Journal of Industrial Systems Engineering and Management, Vol. 2 No. 5, 2014, pp. 1032-1043.

Schwan, Silva, and Batista, Handbook of Plant-Based Fermented Food and Beverage Technology, Brazil: CRC Press, 2012.

Jackels SC, Jackels CF, Characterization of The Coffee Mucilage Fermentation Process Using Chemical Indicators: A Field Study in Nicaragua, J Food Sci, Vol. 70, 2005, pp. 321-325.

Alysouf, Imad, The Role of Maintenance in Improving Companies Productivity and Profitability, International Journal Production Economics, Vol. 105, 2007, pp. 70-78.

Sary, Ratna, Kaji Eksperimental Pengeringan Biji Kopi dengan Menggunakan Sistem Konveksi Paksa, Jurnal Polimesin, Vol. 14 No. 2, 2016, pp. 13-18.

Kamaruddin, Syariazulfa, Mohammad, and Mahbub, Barrier and Impact of Mechanisation and Automation in Construction to Achieve Better Quality Products, Social and Behavioral Sciences, Vol. 222, 2015, pp. 111-120.

Syahri, Heryanto, Wibowo, and Hatmoko, Waste Analysis with Value Stream Mapping in Multi-storey Building Column Work, Journal of Civil Engineering Works, Vol. 6 No. 4, 2017, pp. 192-200.

Mushavhanamadi, Khathutshelo and Selowa, Tumiso Brian, The Impact of Plant Maintenance on Quality Productivity in Gauteng Breweries, Proceedings of the International Conference on Industrial Engineering and Operations Management, 2018, pp. 1743-1753.

Lipinska, Tomaszewska, and Krajewska, Identifying Factors Associated with Food Losses during Transportation: Potentials for Social Purposes, Sustainability, 2019, pp. 1-15.

Villarreal, Garcia, Rosas, Eliminating Transportation Waste in Food Distribution: A Case Study. Transportation Journal Vol. 48 No. 2, 2009, pp. 72-77.

Esa, Rahman, and Jamaludin, Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia, Procedia Social and Behavioral Sciences, Vol. 211, 2015, pp. 215-220.

Sanderson, M. Penelope, The Human Planning and Scheduling Role in Advanced Manufacturing Systems: An Emerging Human Factors Domain, Human Factors, Vol. 31 No. 6, 1989, pp. 635-666.

Mata, Quesada, and Mata-Marin, Can E-Commerce Provide a Solution to the Coffee Paradox, IFIP World Information Technology Forum (WITFOR), 2016, pp. 181-194.

Endar Hidayat, Asmak Afriliana, Gusmini Gusmini, Masuda Taizo, Hiroyuki Harada. 2020. Evaluate of Coffee Husk Compost. International Journal of Food, Agriculture, and Natural Resources. Vol 1 (1):37-43. https://doi.org/10.46676/ij-fanres.v1i1.8

Giuliano Marodin, Alejandro Germán Frank, Guilherme Luz Tortorella, Torbjørn Netland. 2018. Lean product development and lean manufacturing: Testing moderation effects. International Journal of Production Economics. Vol 203. https://doi.org/10.1016/j.ijpe.2018.07.009.




DOI: https://doi.org/10.46676/ij-fanres.v3i2.96

Refbacks

  • There are currently no refbacks.


E-ISSN : 2722-4066

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.