Saidah, Nisaun (2019) Penerapan Metode Six Sigma Sebagai Upaya Meminimasi Defect Produksi Garam Briket di UD. Podo Seneng. Sarjana thesis, Universitas Brawijaya.
Abstract
UD. Podo Seneng merupakan industri yang memproduksi garam. Garam yang di produksi yaitu garam halus, garam briket, dan garam grasak. Dalam proses produksinya masih terdapat permasalahan. Permasalahan yang terjadi yaitu masih tingginya persentase cacat pada garam briket. Hasil identifikasi awal terdapat 2 variasi cacat yaitu garam cacat bentuk dan cacat warna. Produk cacat hanya dicatat saja tanpa dilakukannya perbaikan, oleh karena itu analisis penyebab terjadinya produk cacat dan pengendalian kualitas belum maksimal. Tujuan penelitian ini untuk mengetahui penyebab terjadinya produk cacat sehingga dapat memberikan rekomendasi perbaikan untuk menurunkan jumlah produk cacat. Metode yang digunakan dalam penelitian ini adalah Six Sigma. Six Sigma merupakan metode perbaikan kualitas dengan target 3,4 Defect Per Million Opportunity. Six Sigma terdiri dari tahap define, measure, analyze, improve dan control (DMAIC). Pada penelitian ini hanya sebatas sampai tahap improve. Tahap define yaitu mengidentifikasi permasalahan yang terjadi menggunakan Critical to Quality (CTQ). Tahap measure yaitu mengukur tingkat kinerja saat ini menggunakan peta kendali P, DPMO, level sigma, kapabilitas proses (Cp) dan menghitung biaya kegagalan internal. Tahap analyze yaitu menganalisis penyebab terjadinya permasalahan menggunakan fishbone diagram dan mengetahui penyebab yang paling potensial sehingga dijadikan prioritas perbaikan menggunakan Failure Modes and Effect Anylsis (FMEA). Pada tahap improve diberikan rekomendasi perbaikan untuk menurunkan cacat produk menggunakan kaizen (5S), Checklist Sheet, Poka Yoke dan Stopwatch Time Study. Berdasarkan penelitian yang telah dilakukan, cacat bentuk memiliki Critical to Quality (CTQ) yaitu garam presisi kotak dan keras. Cacat warna memiliki CTQ yaitu garam tidak berwarna coklat kehitaman. Nilai DPMO sebesar 90.210,86, level sigma sebesar 2,839, dan kapabilitas proses (Cp) sebesar 0,946. Berdasarkan perhitungan biaya kegagalan internal, perusahaan mengalami kerugian sebesar Rp 12.788.860. Penyebab terjadinya cacat berdasarkan fishbone diagram yaitu untuk cacat bentuk dipengaruhi oleh faktor manusia, mesin, dan metode. Cacat warna dipengaruhi oleh faktor manusia, mesin, metode, dan material. Penyebab terjadinya cacat yang paling potensial berdasarkan FMEA untuk cacat bentuk yaitu loyang tipis dan lentur, skill operator kurang, serta kesalahan pemindahan garam. Cacat warna disebabkan oleh penghantar panas kurang merata, kurang memantau proses pengovenan, serta peletakan dan pengambilan tidak First In First Out (FIFO). Terdapat 7 rekomendasi perbaikan yaitu mengganti loyang yang tipis dan lentur serta melakukan perawatan loyang berdasarkan metode 5S, melakukan pelatihan operator, membuat rancangan SOP metode pengovenan, membuat rancangan job description operator pengovenan, menentukan jumlah operator pengovenan, menambahkan Jig and Fixture pada proses pencetakan, dan menambahkan pembanding warna kematangan garam (prototype).
English Abstract
UD. Podo Seneng is an industry that produces salt, which are table salt, briquette salt, and coarse salt. There’s still problems in the production process. The problem is the defect of briquette salt still on high persentage. First identification shows that 2 variation defect that is shape defect and color defect. Every defect product recorded manually by the officer and still not implement any improvement yet, therefore analysis of the cause defect product and quality control not maximal. The purpose of this research is to find the causes of product defect. Hopefully, it can provide solutions and recommendations to reduce the defect product. The method used in this research is Six Sigma. Six Sigma is a method of quality improvement with the target 3,4 Defect Per Million Opportunity. Six Sigma itself consists of 6 stages which are Define, Measure, Analyze, Improve, and Control (DMAIC). This research covers the stages until the improve stage. The define stage is to identify the problem using Critical to Quality (CTQ). The measure stage is measure current performance using P-Control Chart, DPMO, Level Sigma, Process Capability (Cp) and calculate internal failure cost. The analyze stage is to analyze the cause of the problem using Fishbone Diagram and find out which cause holds the most potential so as to make it an improvements priority using Failure Modes and Effect Analysis (FMEA). The improve stage given improvement recommendation to lower defects amount using Kaizen (5S), Checklist Sheet, Poka Yoke and Stopwacth Time Study. The result of research, shape defect has the Critical to Quality (CTQ) of accurate boxshaped and hard. Color defect has the CTQ that the color not be brown-black. The DPMO value was 90.210,86, level sigma was 2,839, and Cp in the amount of 0,946. Based on internal failure cost, the industry losses in the amount of Rp 12.788.860. Based on Cause the Fishbone Diagram, the defect for the shape defect was affected by the man, machine, and method factors. Color defect was affected by the man, machine, method, and material factors. Based on FMEA, the cause of defect with the most potential for the shape defect is the thin and flexible brass, less of operator skills, and error when transporting salt. The cause of defect with the most potential for the color defect is that heat transfer is not spread evenly, less of monitoring the oven process, and the storage policy not using First In First Out (FIFO). There are 7 improvement recomendations which are replacing the thin and flexible brass with the addition of brass maintenance using 5S method, training the operators, making SOP design for baking method, making a job description design for baking operators, determining the amount of baking operators, adding Jig and Fixture on the stamping process, and adding correct salt color comparator (prototype).
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2019/560/051905228 |
| Uncontrolled Keywords: | Defect per Million Opportunity (DPMO), DMAIC, Failure Modes and Effect Anylsis (FMEA), Garam Briket, Six Sigma |
| Subjects: | 300 Social sciences > 338 Production > 338.2 Extraction of minerals > 338.27 Products > 338.276 3 Products (Salts) |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Budi Wahyono Wahyono |
| Date Deposited: | 09 Nov 2020 16:50 |
| Last Modified: | 09 Nov 2020 16:50 |
| URI: | http://repository.ub.ac.id/id/eprint/172652 |
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