Waste Analysis in Skin Ointment Production Using Lean Manufacturing and Value Stream Mapping At Pt Xyz Watudakon Plant

Harlindafina P E; Insyirah Putikadea

Authors

Harlindafina P E [email protected]
Insyirah Putikadea Universitas Negeri Surabaya, Indonesia

Keywords:

Lean Manufacturing, Pharmaceutical Industry, Process Cycle Efficiency, Value Stream Mapping, Waste

Abstract

The pharmaceutical industry works in accordance with the Good Manufacturing Practice (GMP), therefore, a portion of the waiting time during production processes cannot be eliminated. This research is intended to determine the types of waste, current state of value stream mapping, analysis of causes, and future state of production for the Salep Kulit XYZ 15 gram ointment at PT XYZ Plant Watudakon. A descriptive qualitative method using Value Stream Mapping (VSM) was employed in this research. Data was gathered from January to May 2026 by observation, stopwatch time measurement, interviews with five informant groups, and documentation. It shows that the total lead time was 102,780 minutes (71.38 days) with a value-added time of 3,120 minutes and PCE was 3.04%. "Waiting" and "inventory" were identified as the two most prevalent forms of waste. The "waiting" waste took place during raw material tests, finished goods tests, purchase order delays owing to cross unit arrears, import delays, and scheduling delays. Root causes include limited QC laboratory capacity, centralization of the ERP system, single-source supplier dependence, and scheduling non-integration. Four specific quantifiable GMP-compliant changes can be expected to cut lead time by 32.40 percent or 69,480 minutes and increase the PCE to 4.23 percent, with a fifth suggestion covering supply chain risks.

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