Hansen, Reynaldo (2021) Analisis Pengendalian Kualitas Dalam Upaya Mengurangi Produk Defect Dengan Pendekatan Six Sigma Pada PT. Tirtamas Lestari Banyuwangi. Sarjana thesis, Universitas Brawijaya.
Abstract
PT Tirtamas Lestari Banyuwangi merupakan salah satu perusahaan yang telah memproduksi produk AMDK sejak 2011 yang terletak di Kabupaten Banyuwangi. PT Tirtamas Lestari Banyuwangi memiliki 4 varian produk AMDK, yaitu kemasan dalam gelas 220ml, botol 600ml, botol 1500ml, dan galon isi ulang 19Liter. Bersumber dari data historis perusahaan pada bulan Januari-November 2020, masih terdapat produk cacat yang terjadi selama proses produksi dimana kemasan gelas 220ml melebihi batas toleransi sebesar 0,5%. Oleh sebab itu, dibutuhkan identifikasi serta pengendalian lebih mendalam terhadap sumber penyebab cacat dan dapat memberikan rekomendasi perbaikan dengan mengimplementasikan metode Six Sigma dengan tujuan untuk mencapai nilai sigma 6 atau 3,4 cacat dari satu juta kesempatan. Dalam penelitian ini tahapan implementasi pengendalian kualitas dengan Six Sigma adalah define, measure, analyze, improve, dan control (DMAIC), namun hingga tahap improve saja. Pada tahap define, berisi mengenai identifikasi Critical to Quality (CTQ) yang menjadi kepuasan konsumen dan perusahaan, identifikasi jumlah cacat tertinggi menggunakan diagram pareto, serta identifikasi elemen-elemen yang terlibat dalam proses produksi menggunakan diagram Supplier-Input-Process-Output-Customer (SIPOC). Tahap measure, berisi mengenai identifikasi batas pengendalian kualitas menggunakan control chart untuk cacat variabel memakai P chart dan untuk cacat variabel memakai X-bar R chart, mengukur nilai Defect per Million Opportunities (DPMO) dan level Sigma, serta membuat scatter diagram. Tahap analyze, berisi mengenai untuk mengetahui akar penyebab masalah yang menimbulkan cacat produk menggunakan fishbone diagram, serta mengidentifikasi apakah terdapat perbedaan rata-rata antara regu karyawan dan persentase cacat produk. Tahap improve, berisi mengenai rekomendasi perbaikan yang dapat dilakukan untuk mengurangi hingga menghilangkan cacat pada produk kemasan gelas 220ml.Berdasarkan hasil penelitian, tahap define didapatkan lima jenis cacat produk kemasan gelas 220ml adalah kemasan double, kemasan bocor, kemasan remuk, cap miring, dan volume air kurang yang juga menjadi critical to quality (CTQ), untuk persentase cacat tertinggi atau prioritas menggunakan pareto diagram adalah jenis cacat kemasan bocor, remuk, dan cap miring. Tahap measure, untuk jenis cacat atribut peta kendali P (kemasan double, kemasan bocor, kemasan remuk, dan cap miring) dapat dilihat dari grafik terdapat satu data pengamatan yang di luar batas kendali yang disebabkan penyebab khusus dan untuk peta jenis cacat variabel peta kendali X-bar R (volume air kurang) dari grafik dapat dilihat terdapat satu data pengamatan yang di luar batas kendali yang disebabkan penyebab khusus. Perhitungan nilai Defect per Million pportunities (DPMO) sebesar 1097,969 dan level Sigma sebesar 4,56. Untuk hasil scatter diagram diperoleh hubungan antara total produk yang diproduksi dengan jumlah cacat yang terjadi adalah korelasi positif namun tidak signifikan. Tahap analyze, diperoleh faktor-faktor penyebab cacat adalah faktor mesin, material, metode, dan manusia, sedangkan hasil pengujian perbedaan rata-rata didapatkan bahwa terjadi perbedaan signifikan antara regu karyawan dengan jumlah cacat yang dihasilkan. Tahap improve, hasil rekomendasi perbaikan diagram PDPC menjawab dari permasalahan yang terdapat pada fishbone diagram yang mana hampir keseluruhan dapat diterima, dan rekomendasi perbaikan menggunakan metode Poka Yoke didapatkan 7 rekomendasi perbaikan antara lain adalah melakukan redesign layout dari workstation packaging kemasan gelas 220ml, menambahkan sensor yang berguna memberikan peringatan jika terjadi fenomena yang tidak diinginkan, membuat poster sebagai tanda dan peringatan, menerapkan budaya 5R, pembuatan check sheet untuk melakukan kontrol terhadap aktivitas maupun jumlah produk, serta melakukan evaluasi pelatihan terhadap karyawan. Dari 7 rekomendasi perbaikan tersebut terpilih 5 usulan yang bisa diterima dan 2 diantara belum bisa segera dilakukan oleh pihak perusahaan.
English Abstract
PT Tirtamas Lestari Banyuwangi is one of the companies that has been producing AMDK products since 2011 which is located in Banyuwangi Regency. PT Tirtamas Lestari Banyuwangi has 4 variants of AMDK products, namely packaging in 220ml glasses, 600ml bottles, 1500ml bottles, and 19Liter refill gallons. Sourced from the company's historical data in January-November 2020, there are still defective products that occur during the production process where the 220ml glass packaging exceeds the tolerance limit of 0.5%. Therefore, it is necessary to identify and control more in-depth the source of the causes of defects and can provide recommendations for improvement by implementing Six Sigma approach with the aim of achieving a value of sigma 6 or 3.4 defects out of one million opportunities. In this research, the stages of implementing quality control with Six Sigma are define, measure, analyze, improve, and control (DMAIC), but only up to the improve stage. In the define stage, it contains identification of Critical to Quality (CTQ) which is the satisfaction of consumers and companies, identification of the highest number of defects using Pareto diagrams, and identification of elements involved in the production process using SupplierInput-Process-Output-Customer diagram (SIPOC). The measure stage, contains the identification of quality control limits using a control chart for variable defects using a P chart and for variable defects using an X-bar R chart, measuring the value of Defects per Million Opportunities (DPMO) and levels Sigma, measuring the value of process capability, and making scatters diagrams. The analyze stage, contains about finding out the root causes of problems that cause product defects using fishbone diagrams, as well as identifying whether there is an average difference between employee teams and the percentage of product defects. The improve stage, contains recommendations for improvements that can be made to reduce to eliminate defects in 220ml glass packaging products. Based on the results of the research, thestage define obtained five types of defects in 220ml glass packaging products, that are packaging double, leaky packaging, crumbled packaging, tilted stamp, and lack of water volume which are also critical to quality (CTQ), for the highest percentage of defects or priorities using the Pareto Diagram. is a type of packaging defect leaking, crumbling, and tilted stamp. The measure stage, for the type of attribute defect P control chart (packaging double, leaky packaging, crumbling packaging, and tilted stamp) can be seen from the graph there is one observation data that is outside the control limits due to special causes and for the type of variable defect X-bar R control chart (lack of water volume) from the graph, it can be seen that there is one observation data that is outside the control limits due to special causes. The calculation of the value of Defects per Million Opportunities (DPMO) is 1097.969, the level Sigma is 4.56, and the process capability is 1.55. For the results of the scatter diagram, the relationship between the total product produced and the number of defects that occur is a positive but not significant correlation. In the analyze stage, obtained the factors that cause defects are machine, material, method, and human factors, while the results of the average difference test that there is a significant difference between employee teams and the number of defects produced. The improve stage, the results of the recommendations for improvement the PDPC diagram answered the problems contained in the fishbone diagram which were almost entirely acceptable, and recommendations for improvement using the Poka Yoke method obtained 7 recommendations for improvement, including redesigning the layout of the workstation 220ml glass packaging, adding sensors that useful for giving warnings in case of unwanted phenomena, making posters as signs and warnings, implementing 5R culture, making check sheets to control activities and the number of products, as well as evaluating training for employees. Of the 7 recommendations for improvement, 5 remendations were selected that could be accepted and 2 of them could not be immediately carried out by the company.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 670 |
| Uncontrolled Keywords: | Pengendalian Kualitas, Kemasan Gelas 220ml, Six Sigma, Produk Defect, Quality Control, 220ml Glass Packaging, Six Sigma, Defect Product, Poka Yoke. |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Unnamed user with email gaby |
| Date Deposited: | 22 Oct 2021 05:48 |
| Last Modified: | 02 Oct 2024 06:33 |
| URI: | http://repository.ub.ac.id/id/eprint/184999 |
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