| This research discusses about a recommendation of production system improvement based on lean manufacturing system. Case study was conducted at PT. Indofood Fritolay Makmur, a company which produce snacks. This company have produced many brands of snacks, one of them is Qtela Kerupuk Keriting. Even this company is one of the leading companies in Indonesia, there are some problems occur. The products amount always out of the target, which is underproduction or overproduction. Besides, there are also some wastes like defect products, idle, inventory, and many more. The shopfloor also not in a good order. The company already use pull system in their production, but it’s performance is not optimum enough. The process cycle efficiency (PCE) current score is only 0,06% so it still unlean. Besides, the overall equipment effectiveness (OEE) current score is only 30%. The cycle time to make a box of Qtela Kerupuk Keriting is 474,83 seconds with 15 days as a lead time. Simulation statistical result also shown that the average of the machines’ utility is about 44,35% and the average machines’ idle time is about 36,79%.An improvement was made using lean manufacturing system tools which are count the takt time and pitch, count the production capacity, design a finished goods supermarket design a raw material supermarket, count the buffer and safety inventories, design a 5S system, design line balancing, fullwork, and workcell, make a work standardization, design paced withdrawal, and planning for the runner. This recommendation made the PCE score increase to 0,31% and OEE score increase to 56%. The cycle time to make one box of QtelaKerupuk Keriting decrease to 238,94 seconds and the lead time decrease to two days. Simulation statistical result shown that the average of the machine’s utility become 29,21% and the average machnie’s idle time become 45,62%. |