Dewi, Galuh Ratna (2014) Implementasi Lean Sigma Untuk Penurunan Nilai Cost Of Poor Quality Kain Ekspor Kelas A (Studi Kasus: Departemen Finishing PT Mertex Indonesia). Sarjana thesis, Universitas Brawijaya.
Abstract
PT Mertex Indonesia merupakan produsen tekstil yang membagi prosesnya ke dalam tiga departemen. Departemen yang bertugas mengolah kain mentah menjadi produk kain jadi siap pakai adalah Departemen Finishing. Dalam menjalankan produksinya saat ini, Departemen Finishing masih mengalami kendala yaitu adanya pemborosan (waste) antara lain berupa defect produk dan scrap yang harus rework. Waste sebagai internal failure menyebabkan adanya cost of poor quality yang membuat perusahaan mengalami opportunity lost income. Agar perusahaan dapat meningkatan kualitas dan menurunkan cost of poor quality yang terjadi saat ini, maka penelitian ini dilakukan dengan menggunakan pendekatan Lean Six Sigma. Pendekatan lean akan mengurangi non value added activity dan membuat value added activity mengalir secara lancar sepanjang value stream, sedangkan six sigma akan meningkatkan kapabilitas proses dan kualitas produk. Integrasi pendekatan lean dan six sigma dalam penelitian ini menggunakan metode DMAI yaitu define, measure, analyze dan improve. Tahap define dilakukan dengan pengukuran waktu baku menggunakan stopwatch time study, pembuatan value stream mapping, identifikasi aktivitas dan waste serta melakukan perhitungan cost of poor quality masing-masing waste. Tahap measure dilakukan dengan menentukan critical waste pada waste berpengaruh, mengukur kapabilitas proses long term dan menghitung nilai sigma. Tahap analyze dilakukan dengan menganalisa penyebab masalah serta menentukan prioritas perbaikan menggunakan failure mode and effect analysis (FMEA). Terakhir tahap improve dilakukan dengan menentukan alternatif perbaikan menggunakan konsep value-based management dan dilakukan pembuatan future state value stream mapping. Dari analisis yang telah dilakukan didapatkan bahwa waste berpengaruh yang terjadi pada Departemen Finishing berdasarkan cost of poor quality adalah waste waiting antrian material, waste inventory dan waste defect. Kinerja proses pada proses produksi kain jenis Ekspor Kelas A dalam Departemen Finishing saat ini bila dilihat dari nilai sigma adalah 3,505 . Sedangkan indeks kapabilitas proses sebesar 0,672 (Cpk < 1) sehingga proses dikatakan tidak capable. Melalui konsep value based management dengan memperhatikan cost dan performansi maka alternatif perbaikan terpilih adalah mengganti proses pengemasan secara manual dengan proses pengemasan secara otomatis dengan membeli mesin pengemas otomatis dan menjaga kestabilan rolling mesin, melakukan preventive maintenance secara teratur dan melakukan pemasangan expander roll pada roll mesin dengan biaya sebesar $2.272.248,97. Setelah dilakukan rekomendasi perbaikan diharapkan nilai sigma dapat meningkat dari 3,505 sigma menjadi 4,84 sigma, indeks kapabilitas proses dapat meningkat dari 0,672 menjadi 0,96 dan cost of poor quality diharapkan dapat menurun sebesar 9,98% untuk waste waiting, 27,71% untuk waste defect serta 51,22% untuk waste inventory.
English Abstract
PT Mertex Indonesia is a textile manufacturer which divides the production process into three departments. Department who serves the process of the raw fabric into a finished fabric products is Finishing Department. Recently, Finishing Department has waste problem. The waste occurs in the process of products defect and scrap that must rework. Waste as an internal failure causes the cost of poor quality which leads the company to get opportunity lost income. In order to improve the quality and reduce the cost of poor quality, this research was conducted by using lean six sigma approach. Lean approach will reduce non-value added activity and create value added activity flows seamlessly throughout the value stream. Meanwhile, six sigma will improve the process of product’s capability and quality. The integration of lean and six sigma approach in this study uses DMAI consisting of define, measure, analyze and improve. Define phase is done by measuring the standard time by using stopwatch time study, create value stream mapping process, waste identification and activity classification as well as calculating the cost of poor quality waste respectively. Measure phase is done by determining the critical impact of waste on the waste, measuring and calculating long term process capability and value of sigma. Analyze phase is done by analyzing the cause of the problem and determining the priority of improvement using failure mode and effect analysis (FMEA). Final stages is improve phase that is performed by determining alternative improvement using the concept of value-based management and making future state value stream mapping process. From the analysis in this research, it was found that the waste that has the greatest influence on the Finishing Department based on the cost of poor quality are waste with the category: waiting queue of materials, inventory and defects. Performance processes in the production process of fabric with the type of Export Class A, when viewed from the sigma value are 3.505σ. Whereas, process capability index is equal to 0.672 (Cpk <1) so that it is defined that the process are not capable. Through the concept of value-based management by taking into account the cost and performance of the selected improvement alternative, the manual packaging processes should be changed into the automatic packaging processes by purchasing automatic packaging machines, maintain the stability of the rolling machine, conduct preventive maintenance regularly and conduct the installation expander roll on roll machine with the cost of $ 2,272,248.97. Having made recommendations for improvement, it is expected to increase the sigma value from 3.505σ to be 4.84 σ, and process capability index increased from 0.672 to be 0.96 and also cost of poor quality is expected to decrease by 9,98% for waiting, 27,71% for defect and 51.22% for inventory.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2014/371/051404816 |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Hasbi |
| Date Deposited: | 22 Aug 2014 14:32 |
| Last Modified: | 15 Nov 2021 05:46 |
| URI: | http://repository.ub.ac.id/id/eprint/142661 |
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