Minimizing Waste in The Bread Production Process with The Waste Assessment Model and Failure Modes and Effect Analysis (FMEA) Method
DOI:
https://doi.org/10.46799/jst.v6i5.1074Keywords:
Minimizing Seven Waste, Bread Production, Waste Assessment Model (WAM), Failure Mode and Effects Analysis (FMEA)Abstract
The achievement of production targets is a key goal for every company. To achieve these targets, it is crucial to enhance efficiency and minimize waste, such as defective products, unnecessary movements, overproduction, and excessive production time. This study aims to identify the types and amounts of waste, analyze the most dominant waste, and compare waste across three similar companies. The identification of waste was conducted using the WAM method across the three companies, revealing five major waste types with the highest percentages: Defect waste (23.489%, 21.144%, and 20.949%), Inventory waste (20.489%, 15.616%, and 18.694%), Overproduction waste (15.749%, 15.480%, and 15.391%), Waiting waste (9.382%, 12.651%, and 13.209%), and Motion waste (13.850%, 11.299%, and 10.739%). The analysis of waste causes used the Failure Mode and Effects Analysis (FMEA) method, where the highest Risk Priority Number (RPN) of 576 was associated with defective products. Recommendations to address this issue include periodic maintenance of oven machines, structured production scheduling, provision of material handling tools, and improvements in the production layout. The most dominant waste across the three companies was Defect waste, with Sarigut Bakery having the highest percentage of waste (23.489%), followed by Nafisah Bakery (21.144%) and Istana Bakery (20.949%). This study highlights the importance of addressing waste to improve production efficiency and achieve production targets.
Downloads
References
Scott, 2012. Production Management Production System Planning. Fourth Edition. Publisher: BPFE. Yogyakarta.
Amri, 2014. Introduction to Industrial Engineering. The University of Wisconsin. Press: Aceh.
Assauri, S. 2016. Production Operations Management Achievement of Sustainable Organizational Goals. Edition 3. PT Raja Grafindo Persada: Jakarta.
Audra, D. 2019. Analysis of Lean Manufacturing to Reduce Waste at Rotte Stores Pekanbaru. Industrial Science and Technology Final Project. Postgraduate Program of Sultan Syarif Kasim State Islamic University, Riau, Pekanbaru.
Fitriadi, 2013. Increasing the Productivity of MSMEsTraditional Aceh Cake (Karah Cake) Through Mechanization of Cake Making Tools. Journal of Industrial Optimization Engineering. Vol. 5. No. 2. Pages 140-147.
Gaspersz, V. 2012. All in one Production and Inventory Management, Edisi kedelapan. Bogor: Vinchristo Publication.
Ginting, R. 2009. Production Systemi. Graha Ilmu : Yogyakarta.
Mulyani, D. 2021. Analysis of Production Patterns in an Effort to Minimize Production Costs at Cahaya Hafidza and Brother's Ponorogo. Management Economics Final Project. Postgraduate Program. University of Muhammadiyah Ponorogo.
Nasution A. H., 2018. Production Planning and Control. Graha Ilmu: Yogyakarta.
Pangestu, S. 2012. Operations Management. BPFE Publisher : Yogyakarta.
Purnomo, H., 2004, "Introduction to Industrial Engineering", Graha ilmu, Yogyakarta.
Nyoman, G. 2015. Optimization Techniques. Udayana University. Press: Denpasar Bali.
Rawabdeh, I. 2005. A Model For The Assessment Of Waste In Job Shop Environment. International Journal of Operations and Production Management. Vol. 5. No. 25. Halaman 800-822.
Render, B. 2015. Operations Management and Supply Chain Sustainability Management. Edition 11. Salemba Empat : Jakarta.
Shigeo, H. 1988. Danwa No Kouzou. Tokyo: Aratake Shuppan.
Subhan, 2015. Increasing Work Productivity by Using the Work Sampling Method in the Brick Industry (Case Study at UD Amin Jaya, Langsa City). Scientific Journal of Engineering. Vol.02. No.02. Pages 1-12.
Sukanto, R. 2012. Production Management Fourth Edition. BPFE Publisher: Yogyakarta.
Sutalaksana, 2006. Work System Design Techniques. ITB. Bandung.
Tarwaka, 2015. Ergonomics for Occupational Health Safety and Productivity. Surakarta: Harapan Press.
Winardi, 2014. Planning and Supervision in the Field of Management. Mandar Maju : Jakarta.
Wignjosoebroto, S. 2008. Ergonomics, Motion and Time Studies. Source: Jakarta.
Womack, J And Jones, D. 2003. Lean Thingking Banis Waste and Create Wealth in Your Corporation. Edition revised and updated. NY: Free Press.
Virarey Mayang, 2022 Identification of Waste in the Nail Production Process Using the Waste Method of the Industrial Engineering Journal. Vol. 5. No. 1. Pages 1-8.
Zahri, C. 2018. Analysis of Production Patterns In order to minimize Production Costs at PT. Main Giant of Medan. Journal of Industrial Engineering. Vol. 15. No. 10. Pages 1829-7463.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Rizki Laturrahmi, Edy Fradinata, Husni
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International.
Authors who publish with this journal agree to the following terms:
- Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution-ShareAlike 4.0 International (CC-BY-SA). that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work.
