Perancangan Sistem Kanban dan 5S sebagai Upaya Pengurangan Waste Overproduction dan Waste Inventory pada UKM Logam
DOI:
https://doi.org/10.59024/jisi.v4i3.2403Keywords:
5S, Kanban, Lean Manufacturing, Waste Inventory, Waste OverproductionAbstract
This study addresses a metal-component SME producing motorcycle rear brake pedals and rings, which faces two primary Waste problems: overproduction Waste resulting in Work-in-process (WIP) accumulation of 31,860 units/day across 16 workstations, and inventory Waste caused by a finished-goods warehouse lacking a storage layout system, storage racks, or clear visual markers. This research aims to design a kanban system and propose 5S improvements as an integrated solution to address both problems. The method used is a quantitative descriptive approach with a case study using February 2026 production data. The kanban system design results show that each workstation requires 3 production kanban cards (P-Kanban) and 3 withdrawal kanban cards (W-Kanban), with container capacities varying across processes. Implementation of the kanban system was able to reduce average WIP by 70% from the initial condition. Meanwhile, the 5S checklist assessment results show an average achievement of 46.7%, with the Seiton, Seiketsu, and Shitsuke phases identified as improvement priorities, each achieving 33.3%. The proposed 5S improvements include the procurement of tiered storage racks with a color-coding system, product zoning, preparation of storage SOPs, and periodic internal audits.
References
Adiansyah, S., & Al Faritsy, A. Z. (2024). Perancangan sistem Kanban untuk mengurangi work in process di lantai produksi. Jurnal Teknologi dan Manajemen Industri Terapan, 3(2), 151–159. https://doi.org/10.55826/jtmit.v3i2.324
Afriandi, F., & Saifuddin, J. A. (2023). Penerapan lean manufacturing menggunakan metode waste assessment model (WAM) untuk mengurangi waste pada lini produksi steel structure. Jurnal Teknik Mesin, Industri, Elektro dan Informatika, 2(4), 62–75. https://doi.org/10.55606/jtmei.v2i4.2930
Ahmad, F. S., & Mukhtar, M. N. A. (2025). Analisis pemborosan proses produksi pedal rem kaki menggunakan lean manufacturing dan value stream mapping di PT Borneo Perkasa, 615–621.
Anwar, C., Suryono, Y. B., & Rani, C. P. (2020). Kanban system analysis and improvement of the supply carset in BMW Logistics at Jakarta Plant using just-in-time (JIT) method, 5(1), 257–265.
Fadilah, M. F., & Wibero, R. (2024). Rancangan lean manufacturing untuk mengurangi pemborosan pada proses pembuatan sepatu dengan pendekatan metode value stream mapping (VSM) dan root cause analysis (RCA) di home industry sepatu. 2(1), 16–25. https://doi.org/10.38035/jgit.v2i1.230
Gupta, S., & Chandna, P. (2020). A case study concerning the 5S lean technique in a scientific equipment manufacturing company. https://doi.org/10.1108/GS-01-2020-0004
Herdiansyah, D. (2020). Perancangan dan penerapan sistem Kanban di PT XY. Jurnal Ilmiah Teknologi Informasi Terapan, 6(2), 57–64. https://doi.org/10.33197/jitter.vol6.iss2.2020.330
Lakshmanan, R., Nyamekye, P., Virolainen, V., & Piili, H. (2023). The convergence of lean management and additive manufacturing: Case of manufacturing industries. Cleaner Engineering and Technology, 13, 100620. https://doi.org/10.1016/j.clet.2023.100620
Mukhtar, M. N. A. (2027). Application of the Kaizen 5S method for the layout of the warehouse section. TiBuana Journal of Applied Industrial Engineering, 3(2), 78–85. https://doi.org/10.36456/tibuana.3.01.2193.1-7
Nandar, N., Sujana, I., & Anggela, P. (2024). Prosedur kerja 5S untuk gudang material dan peralatan kerja PT Bonardo Borneo Mandiri. Jurnal Teknik Industri Universitas Tanjungpura, 8(2).
Natakusumah, H., & Larutama, W. (2026). Pengurangan inventory waste melalui implementasi 5S pada warehouse optimization PT XYZ. Jurnal Bisnis, Logistik dan Supply Chain (BLOGCHAIN), 6(1), 27–32.
Permata, L., Hartanti, S., Gunawan, I., & Mulyana, I. J. (2022). Identification of waste based on lean principles as the way towards sustainability of a higher education institution: A case study from Indonesia. Sustainability, 14(7), 4348. https://doi.org/10.3390/su14074348
Purba, V. C. S., Lalujan, V., & Phangnesia, C. (2024). An implementation of Internet of Things for digitalization of Kanban production system. Jurnal Sistem Cerdas, 7(1), 87–97. https://doi.org/10.37396/jsc.v7i1.383
Putra, O. A., & Prakoso, I. (2020). Penerapan metode klasifikasi ABC dan 5S pada gudang tools PT Mesin Isuzu Indonesia. Jurnal Rekayasa Sistem Industri, 5(2), 90–96. https://doi.org/10.33884/jrsi.v5i2.1906
Raharjo, S. T., Prasetyaningsih, E., & Amaranti, R. (2022). Penyeimbangan lintasan produksi dan perancangan sistem Kanban untuk mengurangi penumpukan work in process pada lini produksi perakitan di PT X. Bandung Conference Series: Industrial Engineering Science, 2(2), 271–281. https://doi.org/10.29313/bcsies.v2i2.3603
Ramadhan, I., & Mahbubah, N. A. (2022). Optimalisasi layout logistik gudang G10 menggunakan integrasi metode 5S dan ABC. Teknika Sains: Jurnal Ilmu Teknik, 7(2), 81–90. https://doi.org/10.24967/teksis.v7i2.1926
Sakti, D. B., Alif, M., Iman, N., Bila, S., & Firdausy, K. (2023). Potensi keberhasilan penerapan just-in-time dalam industri kecil menengah. [Nama jurnal belum tercantum], 1(3), 161–171. https://doi.org/10.58812/smb.v1i03.206
Setiadi, M. A., Novita, C. E., Revaldy, A., Nugroho, A. R., & Purba, H. (2025). Penerapan Seiri, Seiton, Seiso, Seiketsu, Shitsuke (5S) pada industri: Kajian literatur. [Nama jurnal belum tercantum], 9(2), 165–176. https://doi.org/10.35194/jmtsi.v9i2.4925
Tomy Santoso, M., Ferdiyanto Ramadhan, R., Valentina, P. W., & Ali Mukhtar, M. N. (2025). Penerapan konsep lean manufacturing menggunakan metode value stream mapping untuk mengurangi waste pada proses produksi roda apung. Industri Inovatif: Jurnal Teknik Industri, 15(2), 305–313. https://doi.org/10.36040/industri.v15i2.14695
Womack, J. P., & Jones, D. T. (1997). Lean thinking Banish waste and create wealth in your corporation. Journal of the Operational Research Society, 48(11), 1148. https://doi.org/10.1057/palgrave.jors.2600967
Downloads
Published
Issue
Section
License
Copyright (c) 2026 JURNAL ILMIAH TEKNIK INDUSTRI DAN INOVASI
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
