The integrated lean and green manufacturing system: a case study at the peeled loaf production

Abstract

The bakery industries soared as bread become one of the staple food for many people. UD. ABC is one of the bakeries in Banda Aceh that produces various types of bread and jam includes the peeled loaf. Peeled loaf uses many machines for its production process thus will produce waste and consume lots of energy. This study aims to analyze waste and measure energy use in the production process of peeled loaf based on the integrated Lean and Green Manufacturing concept. There are VSM and EVSM as a tool to describe the flow of material and energy usage from the production process. The activities of Value Added (VA), Non-Value Added (NVA) and Necessary Non-Value Added (NNVA) will be analyzed using PAM. The tool for improvement recommendations is five whys analysis. Then, the Future State Map (FSM) shows the improved design with a reduction in the lead time of 20.28 minutes. From this study also obtained the results of saving energy use as much as 0.13 kWh. This energy-saving will realize a lean and environmentally friendly production process at UD. ABC.