Jadwal Training Lean Production & Operation Manufacturing

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Training Lean Production & Operation Manufacturing

Training Lean Production & Operation Manufacturing merupakan program pelatihan profesional yang dirancang untuk meningkatkan kemampuan peserta dalam mengelola proses produksi dan operasional secara efektif, efisien, produktif, serta berorientasi pada peningkatan kualitas dan pengurangan pemborosan.

Dalam lingkungan Manufacturing yang semakin kompetitif, perusahaan dituntut menghasilkan produk berkualitas dengan lead time yang lebih pendek, biaya operasional yang terkendali, inventory yang optimal, produktivitas tinggi, serta kemampuan memenuhi kebutuhan pelanggan secara konsisten. Pendekatan Lean Production dan Lean Manufacturing membantu organisasi mencapai tujuan tersebut dengan mengidentifikasi serta mengurangi aktivitas yang tidak memberikan nilai tambah.

Melalui Training Lean Production & Operation Manufacturing, peserta akan mempelajari prinsip Lean, Value Added dan Non-Value Added Activity, Waste Elimination, Process Flow, Value Stream Mapping, Pull System, Just In Time, Kanban, 5S, Kaizen, Poka-Yoke, Standardized Work, Visual Management, Productivity Improvement, Quality Improvement, serta Continuous Improvement dalam aktivitas produksi dan operasi.

Mengapa Lean Production & Operation Manufacturing Penting?

Permasalahan produksi tidak selalu disebabkan oleh kurangnya mesin atau tenaga kerja. Banyak masalah muncul akibat waiting time, excessive inventory, unnecessary transportation, unnecessary motion, overproduction, overprocessing, defect, rework, bottleneck, setup time yang panjang, dan aliran proses yang tidak efisien.

Lean Production membantu perusahaan melihat proses berdasarkan customer value dan menghilangkan aktivitas yang tidak memberikan nilai tambah. Dengan penerapan Lean yang tepat, organisasi dapat membangun proses yang lebih sederhana, cepat, fleksibel, stabil, dan produktif.

Tujuan Training

Memahami konsep Lean Production dan Lean Manufacturing.
Memahami prinsip dasar Lean Thinking.
Mampu mengidentifikasi Value Added dan Non-Value Added Activity.
Mampu mengidentifikasi waste dalam proses produksi.
Mampu melakukan Process Mapping.
Memahami Value Stream Mapping.
Mampu mengidentifikasi bottleneck dan process constraint.
Memahami konsep Flow dan Pull System.
Memahami Just In Time dan Kanban.
Mampu meningkatkan produktivitas proses produksi.
Mampu mengurangi defect, reject, rework, dan scrap.
Memahami konsep 5S / 5R.
Memahami Kaizen dan Continuous Improvement.
Memahami Poka-Yoke / Mistake Proofing.
Memahami Standardized Work.
Mampu mengembangkan improvement pada proses produksi dan operasi.

Materi Training Lean Production & Operation Manufacturing

1. Introduction to Lean Production & Manufacturing

Pengertian Lean Production.
Pengertian Lean Manufacturing.
Tujuan Lean Manufacturing.
Konsep Productivity, Quality, Cost & Delivery.
Customer Value.
Process Efficiency.
Operational Excellence.
Continuous Improvement.

2. Fundamental Lean Thinking

Specify Value.
Identify Value Stream.
Create Flow.
Establish Pull.
Pursue Perfection.

Lean Thinking mengarahkan organisasi untuk memahami nilai dari perspektif pelanggan dan membangun proses yang mampu menghasilkan nilai tersebut dengan penggunaan sumber daya yang lebih efektif.

3. Customer Value

Customer Requirement.
Customer Expectation.
Quality Requirement.
Delivery Requirement.
Cost Requirement.
Customer Satisfaction.

Value Added & Non-Value Added Activity

4. Understanding Process Activity

Value Added Activity.
Non-Value Added Activity.
Necessary Non-Value Added Activity.
Waste Identification.
Process Simplification.
Process Improvement.

Peserta belajar membedakan aktivitas yang benar-benar menciptakan nilai bagi pelanggan dengan aktivitas yang menggunakan waktu, tenaga, material, ruang, maupun biaya tetapi tidak meningkatkan nilai produk.

Waste Identification & Elimination

5. Seven Wastes dalam Manufacturing

Transportation – perpindahan material yang tidak diperlukan.
Inventory – persediaan yang berlebihan.
Motion – pergerakan operator yang tidak memberikan nilai tambah.
Waiting – waktu tunggu operator, mesin, material, atau informasi.
Overproduction – produksi lebih cepat atau lebih banyak dari kebutuhan.
Overprocessing – proses berlebih yang tidak memberikan nilai tambah.
Defects – reject, rework, scrap, dan kesalahan proses.

6. Eighth Waste – Underutilized Talent

Unused Employee Knowledge.
Unused Employee Creativity.
Lack of Employee Involvement.
Improvement Suggestion.
Employee Empowerment.

Process Mapping

7. Understanding Production Process

Process Input.
Process Activity.
Process Output.
Supplier.
Customer.
Process Boundary.
Process Flow.
Critical Process.

8. SIPOC Analysis

Supplier.
Input.
Process.
Output.
Customer.

Value Stream Mapping (VSM)

9. Current State Value Stream Mapping

Product Family.
Customer Demand.
Production Process.
Material Flow.
Information Flow.
Cycle Time.
Lead Time.
Inventory.
Waiting Time.
Value Added Time.
Non-Value Added Time.

Value Stream Mapping membantu peserta melihat keseluruhan aliran material dan informasi sehingga waste, inventory, waiting, bottleneck, dan peluang improvement dapat terlihat dengan lebih jelas.

10. Future State Value Stream Mapping

Current State Analysis.
Waste Elimination.
Flow Improvement.
Inventory Reduction.
Lead Time Reduction.
Future State Design.
Improvement Action Plan.

Production Flow Improvement

11. Continuous Flow

Process Flow.
One Piece Flow Awareness.
Work Flow.
Material Flow.
Reducing Waiting.
Reducing WIP.
Reducing Bottleneck.

12. Takt Time, Cycle Time & Lead Time

Customer Demand.
Available Production Time.
Takt Time.
Cycle Time.
Lead Time.
Process Capacity.
Production Balance.

13. Bottleneck Analysis

Identify Process Constraint.
Capacity Constraint.
Machine Constraint.
Manpower Constraint.
Material Constraint.
Process Improvement.

Pull System

14. Push vs Pull Production

Push Production.
Pull Production.
Customer Demand.
Inventory Control.
Production Synchronization.
Reducing Overproduction.

Just In Time (JIT)

15. Fundamental Just In Time

Right Product.
Right Quantity.
Right Time.
Inventory Reduction.
Production Flow.
Supplier Coordination.
Customer Demand.

Kanban System

16. Kanban for Production Control

Kanban Concept.
Production Kanban.
Withdrawal Kanban.
Visual Signal.
Material Replenishment.
WIP Control.
Pull Production.

Production Planning & Scheduling

17. Lean Production Planning

Demand Requirement.
Production Capacity.
Production Schedule.
Workload.
Material Requirement.
Production Priority.
Schedule Control.

18. Production Leveling – Heijunka Awareness

Production Leveling.
Volume Leveling.
Product Mix.
Reducing Production Fluctuation.
Workload Stability.
Flow Stability.

Workplace Organization – 5S / 5R

19. Implementasi 5S dalam Manufacturing

Seiri / Ringkas.
Seiton / Rapi.
Seiso / Resik.
Seiketsu / Rawat.
Shitsuke / Rajin.

5S membantu menciptakan area kerja yang lebih terorganisir, mudah dikendalikan, aman, produktif, dan mendukung implementasi Lean Manufacturing.

Visual Management

20. Visual Control dalam Production

Visual Standard.
Visual Indicator.
Production Board.
KPI Board.
Status Production.
Quality Status.
Abnormality Identification.
Andon Awareness.

Standardized Work

21. Standardisasi Proses Kerja

Standard Work Sequence.
Standard Cycle Time.
Standard WIP.
Work Instruction.
Standard Operating Procedure.
Best Known Method.
Process Consistency.

Standardized Work membantu menjaga konsistensi proses dan menjadi baseline untuk melakukan improvement berikutnya.

Kaizen & Continuous Improvement

22. Kaizen Mindset

Small Continuous Improvement.
Employee Involvement.
Problem Identification.
Improvement Ideas.
PDCA.
Standardization.
Continuous Improvement Culture.

23. PDCA Cycle

Plan – mengidentifikasi masalah dan merencanakan improvement.
Do – mengimplementasikan solusi.
Check – mengevaluasi hasil.
Act – melakukan standardisasi atau improvement berikutnya.

Gemba Kaizen

24. Go to Gemba

Go to the Actual Place.
Observe Actual Process.
Understand Actual Condition.
Collect Facts.
Identify Waste.
Identify Abnormality.
Develop Improvement.

Poka-Yoke / Mistake Proofing

25. Defect Prevention

Human Error.
Process Error.
Error Prevention.
Error Detection.
Defect Prevention.
Mistake Proofing.
Zero Defect Awareness.

Quality at the Source

26. Built-In Quality

Do It Right the First Time.
Defect Prevention.
Source Inspection.
Stop and Correct.
Process Ownership.
Quality Responsibility.

Jidoka Awareness

Autonomation.
Abnormality Detection.
Stop the Process.
Problem Visibility.
Immediate Corrective Action.
Prevent Defect Flow.

Root Cause Analysis

27. Structured Problem Solving

Problem Definition.
Symptom vs Root Cause.
Potential Cause.
Fishbone Diagram.
5 Whys.
Pareto Analysis.
Root Cause Verification.
Corrective Action.

Total Productive Maintenance Awareness

28. Equipment Reliability dalam Lean Production

Machine Availability.
Equipment Reliability.
Breakdown Reduction.
Minor Stop Reduction.
Autonomous Maintenance Awareness.
Preventive Maintenance Awareness.
Overall Equipment Effectiveness Awareness.

Overall Equipment Effectiveness (OEE)

Availability.
Performance.
Quality.
Equipment Losses.
Downtime.
Speed Loss.
Quality Loss.
Equipment Performance Improvement.

Quick Changeover / SMED Awareness

29. Setup Time Reduction

Setup Activity.
Internal Setup.
External Setup.
Setup Time Reduction.
Standardized Setup.
Production Flexibility.
Smaller Batch Size.

Inventory Reduction

30. Lean Inventory Management

Raw Material Inventory.
Work In Process.
Finished Goods.
Excess Inventory.
Inventory Carrying Cost.
Material Flow.
Inventory Reduction.

Line Balancing Awareness

Work Element.
Cycle Time.
Workstation Load.
Production Capacity.
Workload Balance.
Bottleneck Reduction.
Productivity Improvement.

Lean Performance Measurement

31. KPI Lean Manufacturing

Productivity.
Output.
Yield.
Defect Rate.
Reject Rate.
Rework Rate.
Cycle Time.
Lead Time.
Inventory Level.
Downtime.
OEE.
On-Time Delivery.

Lean Manufacturing & Cost Reduction

Lean Manufacturing membantu Cost Reduction dengan mengurangi waste, excessive inventory, defect, rework, scrap, waiting, unnecessary movement, excessive processing, downtime, dan berbagai aktivitas Non-Value Added.

Lean Manufacturing & Quality Improvement

Lean Production tidak hanya berorientasi pada kecepatan. Proses yang lebih sederhana, stabil, terstandardisasi, dan memiliki Quality at the Source membantu meningkatkan konsistensi kualitas serta mengurangi defect.

Lean Manufacturing & Productivity Improvement

Produktivitas dapat ditingkatkan dengan memperbaiki flow, mengurangi waiting, mengurangi unnecessary motion, menghilangkan bottleneck, menyeimbangkan workload, memperbaiki machine availability, dan mengurangi aktivitas yang tidak memberikan nilai tambah.

Lean Manufacturing & PPIC

Lean Manufacturing berkaitan erat dengan Production Planning & Inventory Control karena production planning, material availability, inventory level, production scheduling, capacity, dan customer demand memengaruhi kelancaran aliran produksi.

Lean Manufacturing & Supply Chain

Penerapan Lean pada proses produksi membutuhkan dukungan Supply Chain yang responsif. Supplier performance, material delivery, inventory, logistics, warehouse, dan production requirement perlu dikelola secara terintegrasi untuk mendukung flow.

Lean Manufacturing & Warehouse

Warehouse mendukung Lean Production melalui material availability, inventory accuracy, efficient material movement, FIFO/FEFO sesuai kebutuhan, visual management, location management, dan replenishment yang mendukung kebutuhan produksi.

Lean Manufacturing & Maintenance

Machine breakdown dan equipment instability dapat menghambat flow produksi. Karena itu, Lean Manufacturing perlu didukung oleh Maintenance Management dan peningkatan equipment reliability.

Lean Manufacturing & Quality Control

Quality Control mendukung Lean dengan mencegah defect bergerak ke proses berikutnya, mempercepat feedback terhadap abnormality, dan mendukung Root Cause Analysis serta Corrective Action.

Lean Manufacturing & Six Sigma

Lean berfokus pada pengurangan waste dan peningkatan flow, sedangkan Six Sigma berfokus pada pengurangan variation dan defect. Kedua pendekatan dapat diintegrasikan menjadi Lean Six Sigma untuk mendukung Process Improvement berbasis data.

Lean Production Improvement Roadmap

Tahap	Aktivitas
1. Identify Value	Memahami customer requirement dan value yang diharapkan.
2. Map Process	Memetakan aliran proses, material, dan informasi.
3. Identify Waste	Mengidentifikasi aktivitas Non-Value Added dan Seven Wastes.
4. Analyze	Menganalisis bottleneck, waiting, inventory, defect, dan Root Cause.
5. Improve Flow	Memperbaiki flow, layout, workload, material movement, dan proses kerja.
6. Standardize	Membuat Standardized Work, Visual Control, SOP, dan Work Instruction.
7. Sustain	Monitoring KPI dan menjalankan Continuous Improvement.

Workshop Lean Production & Operation Manufacturing

Mapping Production Process.
Value Added & Non-Value Added Analysis.
Seven Wastes Identification.
Current State Value Stream Mapping.
Bottleneck Analysis.
Production Flow Analysis.
Root Cause Analysis.
Waste Elimination.
Future State Design.
Lean Improvement Prioritization.
Action Plan.

Kompetensi yang Dikembangkan

Lean Production.
Lean Manufacturing.
Lean Operation.
Waste Identification.
Waste Reduction.
Value Stream Mapping.
Process Mapping.
Process Flow Improvement.
Just In Time.
Kanban.
5S / 5R.
Kaizen.
Poka-Yoke.
Visual Management.
Standardized Work.
Root Cause Analysis.
Productivity Improvement.
Quality Improvement.
Cost Reduction.
Continuous Improvement.

Target Peserta Training

Training Lean Production & Operation Manufacturing relevan bagi Manager, Supervisor, Section Head, Team Leader, dan Staff yang terkait dengan Production, Manufacturing, Operations, Engineering, Quality Control, Quality Assurance, PPIC, Maintenance, Warehouse, Supply Chain, Industrial Engineering, Process Engineering, Continuous Improvement, dan Operational Excellence.

Pembicara / Fasilitator

Ir. Rachmat Boerhan, CHRP, CHT, CPM, CSCP
Johnson Alvonco, Ph.D. – Alternatif Trainer

Metode Training

Interactive Presentation.
Group Discussion.
Lean Manufacturing Case Study.
Waste Identification Exercise.
Process Mapping.
Value Stream Mapping Exercise.
Root Cause Analysis.
Production Improvement Workshop.
Action Plan.

Jadwal Training Lean Production & Operation Manufacturing

Periode	Tanggal Pelaksanaan
September 2026	29–30 September 2026
Oktober 2026	14–15 Oktober 2026
November 2026	03–04 November 2026
Desember 2026	02–03 Desember 2026
Januari 2027	07–08 Januari 2027
Februari 2027	05–06 Februari 2027
Maret 2027	10–11 Maret 2027
April 2027	06–07 April 2027
Mei 2027	18–19 Mei 2027
Juni 2027	08–09 Juni 2027
Juli 2027	22–23 Juli 2027

Catatan: Jadwal di atas mengikuti halaman khusus Lean Production & Operation Manufacturing Johnson Indonesia. Jadwal dapat mengalami penyesuaian sehingga peserta disarankan melakukan konfirmasi sebelum pendaftaran.

Tempat Training

Alternatif lokasi Offline Training meliputi Ciputra Hotel, Ibis Group, Hotel Oria Jakarta, dan Hotel Holiday Inn Jakarta Wahid Hasyim. Lokasi pelaksanaan akan dikonfirmasikan kembali kepada peserta.

Metode Pelaksanaan

Offline Training – Hotel / Johnson Training Center.
Online Training – Zoom Meeting.
Public Training – mengikuti jadwal Johnson Indonesia.
Private Training – kelas khusus sesuai kebutuhan perusahaan.
In-House Training – materi dan studi kasus dapat disesuaikan dengan proses perusahaan.

Fee Investasi Training

Offline Training Jakarta

Rp5.950.000/orang / 2 hari. Minimal pengiriman 3 peserta dan PASTI RUNNING di hotel.

Investasi termasuk Seminar Kit, Certificate, Lunch, Snack, dan Souvenir.

Offline Training Luar Kota Jakarta

Rp12.000.000/orang – PASTI RUNNING.
Rp8.500.000/orang – pengiriman 1–5 peserta.
Rp8.000.000/orang – pengiriman di atas 5 peserta.
Termasuk Seminar Kit, Certificate, Lunch, Snack, dan Souvenir.

Private Onsite Training

Rp8.000.000/orang / 2 hari – PASTI RUNNING.
Rp5.950.000/orang / 1 hari – PASTI RUNNING.
Lokasi: Training Center Johnson Indonesia.
Termasuk Seminar Kit, Certificate, Lunch, Snack, dan Souvenir.

Online Training

Rp5.500.000/orang / 2 hari, pukul 09.00–16.00 WIB.

Daftar Client Johnson Indonesia

Daftar perusahaan dan institusi yang telah menggunakan layanan training Johnson Indonesia dapat dilihat melalui Daftar Client Johnson Indonesia.

Public Training Lean Production & Operation Manufacturing

Johnson Indonesia menyediakan Public Training Lean Production & Operation Manufacturing bagi profesional Production, Manufacturing, Operations, Engineering, Quality, PPIC, Maintenance, Warehouse, dan Continuous Improvement yang ingin meningkatkan efisiensi serta produktivitas proses.

In-House Training Lean Production & Operation Manufacturing

In-House Training Lean Production & Operation Manufacturing dapat disesuaikan dengan kondisi aktual perusahaan seperti production flow, machine capacity, inventory, layout, material movement, bottleneck, defect, downtime, waiting time, productivity, lead time, dan improvement target.

Perusahaan dapat menggunakan kasus aktual sebagai bahan workshop sehingga peserta dapat mempraktikkan Process Mapping, Waste Identification, Value Stream Mapping, Root Cause Analysis, Future State Design, dan Lean Improvement Action Plan berdasarkan kondisi nyata di tempat kerja.

Training Terkait – Internal Link

Lean Production Action Plan

Pada akhir training, peserta dapat menyusun Lean Production Improvement Action Plan yang mencakup Current Condition, Customer Value, Process Mapping, Waste Identification, Root Cause, Improvement Priority, Future State, Target KPI, PIC, Target Completion, Monitoring, dan Standardization.

Mengapa Memilih Johnson Indonesia?

Johnson Indonesia – Training Provider Since 2002 menyediakan Public Training, In-House Training, Corporate Training, Private Training, Offline Training, dan Online Training untuk pengembangan kompetensi Production, Manufacturing, Operations, Quality, Lean Manufacturing, Supply Chain, PPIC, Warehouse, Continuous Improvement, dan Operational Excellence.

Melalui Training Lean Production & Operation Manufacturing, peserta memperoleh pemahaman mengenai Lean Thinking, Value Added & Non-Value Added Activity, Seven Wastes, Process Mapping, Value Stream Mapping, Flow, Pull System, Just In Time, Kanban, 5S, Kaizen, Visual Management, Standardized Work, Poka-Yoke, Root Cause Analysis, dan Continuous Improvement.

Pendaftaran Training Lean Production & Operation Manufacturing

Tingkatkan kemampuan tim dalam mengurangi waste, meningkatkan produktivitas, memperbaiki flow produksi, mengurangi inventory dan lead time, meningkatkan kualitas, serta membangun proses Manufacturing yang lebih efektif melalui Training Lean Production & Operation Manufacturing Johnson Indonesia.