Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction
In pharmaceutical manufacturing, inefficiencies such as waiting times, excessive material usage, and packaging defects can significantly impact productivity and quality. This study adopts a Lean Six Sigma approach, integrating lean manufacturing and six sigma methodologies, to systematically address...
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| Format: | Article |
| Language: | English |
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Universitas Ahmad Dahlan
2024-10-01
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| Series: | Spektrum Industri: Jurnal Ilmiah Pengetahuan dan Penerapan Teknik Industri |
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| Online Access: | https://journal3.uad.ac.id/index.php/spektrum/article/view/199 |
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| author | Rindi Kusumawardani Adiyodha Ayudha Widyatmoko |
| author_facet | Rindi Kusumawardani Adiyodha Ayudha Widyatmoko |
| author_sort | Rindi Kusumawardani |
| collection | DOAJ |
| description | In pharmaceutical manufacturing, inefficiencies such as waiting times, excessive material usage, and packaging defects can significantly impact productivity and quality. This study adopts a Lean Six Sigma approach, integrating lean manufacturing and six sigma methodologies, to systematically address these challenges. Through Process Activity Mapping (PAM), it was determined that value-added (VA) activities account for approximately 63% of total production activities, while non-value-added (NVA) and essential non-value-added (ENVA) activities contribute about 34% and 4%, respectively. Critical waste was identified using the genba shikumi method, followed by Failure Modes and Effects Analysis (FMEA) to determine Risk Priority Numbers (RPNs). Fuzzy logic was applied to prioritize the suggested improvements for more accurate risk assessments. Key recommendations based on Fuzzy RPN rank include, enhancing bulk product quality before printing, implementing rigorous inspections of the printing process, optimizing machine utilization, and adjusting production schedules using the Shortest Processing Time (SPT) method. |
| format | Article |
| id | doaj-art-73b78773e9ee41fc88ec76456b2542e4 |
| institution | DOAJ |
| issn | 1693-6590 2442-2630 |
| language | English |
| publishDate | 2024-10-01 |
| publisher | Universitas Ahmad Dahlan |
| record_format | Article |
| series | Spektrum Industri: Jurnal Ilmiah Pengetahuan dan Penerapan Teknik Industri |
| spelling | doaj-art-73b78773e9ee41fc88ec76456b2542e42025-08-20T03:07:06ZengUniversitas Ahmad DahlanSpektrum Industri: Jurnal Ilmiah Pengetahuan dan Penerapan Teknik Industri1693-65902442-26302024-10-0122217919210.12928/si.v22i2.199199Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste ReductionRindi Kusumawardani0Adiyodha Ayudha WidyatmokoInstitut Teknologi Sepuluh NopemberIn pharmaceutical manufacturing, inefficiencies such as waiting times, excessive material usage, and packaging defects can significantly impact productivity and quality. This study adopts a Lean Six Sigma approach, integrating lean manufacturing and six sigma methodologies, to systematically address these challenges. Through Process Activity Mapping (PAM), it was determined that value-added (VA) activities account for approximately 63% of total production activities, while non-value-added (NVA) and essential non-value-added (ENVA) activities contribute about 34% and 4%, respectively. Critical waste was identified using the genba shikumi method, followed by Failure Modes and Effects Analysis (FMEA) to determine Risk Priority Numbers (RPNs). Fuzzy logic was applied to prioritize the suggested improvements for more accurate risk assessments. Key recommendations based on Fuzzy RPN rank include, enhancing bulk product quality before printing, implementing rigorous inspections of the printing process, optimizing machine utilization, and adjusting production schedules using the Shortest Processing Time (SPT) method.https://journal3.uad.ac.id/index.php/spektrum/article/view/199lean manufacturingsix sigmalean six sigmafuzzy fmeaproduction process |
| spellingShingle | Rindi Kusumawardani Adiyodha Ayudha Widyatmoko Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction Spektrum Industri: Jurnal Ilmiah Pengetahuan dan Penerapan Teknik Industri lean manufacturing six sigma lean six sigma fuzzy fmea production process |
| title | Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction |
| title_full | Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction |
| title_fullStr | Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction |
| title_full_unstemmed | Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction |
| title_short | Enhancing Pharma Manufacturing Efficiency: Integrating Lean Six Sigma and Fuzzy FMEA for Waste Reduction |
| title_sort | enhancing pharma manufacturing efficiency integrating lean six sigma and fuzzy fmea for waste reduction |
| topic | lean manufacturing six sigma lean six sigma fuzzy fmea production process |
| url | https://journal3.uad.ac.id/index.php/spektrum/article/view/199 |
| work_keys_str_mv | AT rindikusumawardani enhancingpharmamanufacturingefficiencyintegratingleansixsigmaandfuzzyfmeaforwastereduction AT adiyodhaayudhawidyatmoko enhancingpharmamanufacturingefficiencyintegratingleansixsigmaandfuzzyfmeaforwastereduction |