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Instant Removal of Non-Value Add for Pharmaceutical Industries

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Half Day Executive Briefing: Lean Pharma Series

Pada tanggal 16 Februari lalu, SSCX menyelenggarakan mini-briefing yang bertajuk “Instant Removal of Non-Value Add for Pharmaceutical Industries” sebagai bagian dari Lean Pharma Series. Acara yang dihadiri oleh plant dan production manager dari perusahaan-perusahaan farmasi terkemuka di Indonesia ini bertujuan untuk memunculkan urgensi untuk menghilangkan waste yang kerap terjadi dalam operasional pabrik obat dan produk kesehatan, dan meningkatkan efisiensi proses. Tujuan akhirnya adalah Operational Excellence, sustainability dan profitability.
Pada seminar yang diselenggarakan di Harris Hotel Sentul ini, konsultan senior SSCX, Riyantono, membuka pembicaraan dengan menjelaskan tentang beberapa tantangan yang muncul di industri farmasi, seperti kerugian yang terjadi akibat pergantian mesin dan pembersihan mesin, kerugian yang terjadi akibat cacat produk dan pengerjaan ulang, kerugian akibat kerusakan mesin dan penurunan kecepatan kerja (idle/loss speed time), proses leadtime yang panjang, penumpukan inventori, serta biaya operasional yang tidak kompetitif. Sebagai bagian dari program eliminasi waste, dijabarkan pula mengenai value dan waste, termasuk 7 waste (inventory, motion, waiting time, defective products, transportation, overprocess, overproduction) yang merupakan non-value added activity.
Riyantono menjelaskan mengenai Lean, yang merupakan metode solusi dalam menghilangkan kerugian-kerugian (waste) yang kerap terjadi di industri farmasi. Beberapa tool Lean yang disajikan antara lain Value Stream Map (VSM), yang berfungsi meningkatkan kegunaan dari proses mapping dengan menambahkan data seperti material, arus informasi, parameter operasional, leadtime, dan sebagainya.
Selama seminar berlangsung, dijelaskan pula langkah-langkah dalam menggunakan tool VSM tersebut. Langkah awal membuat VSM antara lain membuat SIPOC Chart dan Top-Down Chart. SIPOC Chart adalah singkatan dari Supplier-Input-Process-Output-Customer. Langkah selanjutnya adalah dengan membuat pengelompokan produk dan membuat gambar arus proses serta arus material dan informasi.
Setelah semua arus terpetakan, aktifitas dilanjutkan dengan pengumpulan data untuk proses, seperti inventory, data customer, pengiriman barang, arus material dan data proses.
Diantara penjelasan mengenai langkah-langkah pembuatan VSM tersebut, dijabarkan pula mengenai Process Cycle Time (PCE) yaitu ukuran efisiensi relatif yang ada dalam sebuah proses. PCE mewaliki presentase waktu yang dipergunakan untuk menambah nilai pada produk, dibandingkan dengan total waktu yang diperlukan produk selama masa proses. PCE merupakan indikator kinerja dalam semua proses. Setelah PCE diketahui, langkah dilanjutkan dengan membuat verifikasi peta aktual, dan VSM dapat dikatakan telah terbentuk.
Pada akhir sesi briefing, Riyantono memberikan tips-tips dalam membuat VSM yang baik dan benar, juga mengenai basic tools untuk meningkatkan PCE.
Executive Briefing lainnya yang juga diselenggarakan oleh SSCX yaitu mengenai penerapan Lean dalam industri manufaktur secara umum dan industri packaging. Ulasan mengenai briefing lainnya akan disajikan dalam majalah Shift edisi selanjutnya.

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