Optimisation of Production at Incipono Frozen Food Company using the Lean Manufacturing Method

Abstract

Competition in the food industry compels companies to enhance productivity and production process efficiency to meet consumer demands. One strategy involves implementing Lean Manufacturing concepts to identify and minimize waste occurring during production. This study aims to analyze the current state of the INCIPONO dim sum production process using Value Stream Mapping, identify types of waste using Value Stream Analysis Tools, schedule machinery maintenance, and design improvement proposals to boost production efficiency. A descriptive research method with a qualitative approach was employed. Data collection involved direct observation, interviews, documentation, and production process time measurements. The analysis began with a Time Study to measure process times, followed by mapping information and material flows using Miro, and identifying Value-Added, Necessary Non-Value-Added, and Non-Value-Added activities via Process Activity Mapping. Subsequently, improvement proposals based on Lean Manufacturing principles were formulated, covering a Kaizen Blueprint, 5S implementation, Standard Operating Procedures, Daily Activity planning, Preventive Maintenance, and Manpower Planning. The results indicate that the INCIPONO dim sum production process still contains waste predominantly waiting, motion, transportation, and inventory preventing optimal production flow. The proposed improvements enhance production effectiveness by reorganizing work activities, balancing the workforce, implementing work standards, and establishing periodic machine maintenance. Furthermore, implementing these proposals resulted in a reduction of Direct Labor Costs from IDR 78,300,000 to IDR 42,450,000, representing an efficiency gain of 45.79%. The study demonstrates that applying Lean Manufacturing can improve production efficiency, reduce waste, and support increased productivity for INCIPONO dim sum.