The implementation of lean manufacturing to reduce waste at Pt. Charoen Pokphand Jaya Farm 3 Pekanbaru

PT. Charoen Pokphand Jaya Farm 3 Pekanbaru at Riau Province, Indonesia is a company engaged in poultry farming that produces eggs for hatching again. In the production process of hatching eggs, chickens as egg producers often experience depletion, and the eggs produced do not always reach the category that has been set by the company. The purpose of this research is to reduce the waste that occurs at PT. Charoen Pokphand Jaya Farm 3 Pekanbaru. The method used is a lean manufacturing approach with Value Stream Mapping (VSM) tools for mapping production flow and information flow, as well as Failure Mode and Effects Analysis (FMEA) analysis to determine the causes of process failures that occur in the production line. Waste identification begins with a description of the current state map, then waste analysis is carried out into the seven-waste category. The next step is to analyze the root causes of waste using fishbone diagrams, and FMEA analysts to find out the highest RPN value. The highest RPN value is 448 for the engine category and the Lory Unstable event and the lowest RPN value is the material category with Thin Husk and oxygen-poor water with a value of 60. For recommendations for improvement using the fault tree analysis (FTA) method, there are 20 basic events from determining the cut set that causes defective eggs, while for the depletion of chickens there are 15 basic events that cause a reduction in the chicken population. With the number of basic events that have been identified, suggestions for improvement are given including: training, material improvement and work advice.