Nino, Vinsensa Gerosa Sabu and Dr. Sucipto, STP, MP and Riska Septifani, STP, MP. (2022) Pengendalian Kualitas Produksi Cokelat Bubuk Menggunakan Metode Six Sigma, Failure Mode And Effect Analysis (FMEA), dan Fault Tree Analysis (Studi Kasus Kelompok Tani Mulyo Jati, Mojokerto, Jawa Timur). Sarjana thesis, Universitas Brawijaya.
Abstract
Kakao berperan penting di Indonesia dengan jumlah produksi 728.046 ton per tahun 2021 (Ditjenbun, 2021). Salah satu produk turunan biji kakao ialah cokelat bubuk yang dianggap menyehatkan tubuh karena kandungan polifenolnya. Kelompok Tani Mulyo Jati Mojokerto memproduksi produk olahan kakao termasuk cokelat bubuk. Masih sering ditemukan penyimpangan seperti biji tidak terpecah saat pemecahan biji, biji asing atau kotoran pada hasil roasting, berat produk akhir tidak sesuai, dan kemasan sobek. Masalah tersebut perlu diidentifikasi penyebab dan dicari solusi perbaikannya. Tujuan penelitian ialah mengidentifikasi penyimpangan dominan, penyebab dari tiap jenis penyimpangan dan merancang usulan perbaikannya. Metode pada penelitian ini yakni Six Sigma, Failure Mode and Effect Analysis serta Fault Tree Analysis. Pendekatan Six Sigma berperan meminimalisir variasi seluruh proses dengan konsep DMAI (Define, Measure, Analyze dan Improve). Metode ini diintegrasikan dengan FMEA untuk identifikasi peluang kegagalan selama proses produksi. Penyebab kegagalan dominan yang berdampak besar akan diketahui melalui RPN tertinggi. Selain itu dalam merancang usulan perbaikan digunakan FTA untuk mengetahui penyebab kegagalan secara rinci dari kegagalan paling dasar, sehingga usulan yang diberikan dapat sesuai dan diharapkan mampu mengatasi penyebab penyimpangan. Hasil analisis menunjukkan terdapat tiga jenis penyimpangan dominan pada produksi cokelat bubuk yaitu biji tidak terpecah sempurna, biji utuh hasil roasting dan berat produk cokelat bubuk varian dark, milk dan hazelnut tidak sesuai. Proses pemecahan biji, roasting, dan pengemasan usaha Kelompok Tani Mulyo Jati memiliki nilai sigma 3,05; 4,57; dan 3,29 yang menunjukkan bahwa produksi cokelat bubuk masih kompetitif di industri pangan Indonesia. Metode FMEA disusun untuk mengetahui prioritas penyimpangan dominan dengan diperoleh hasil peringkat tertinggi perhitungan RPN sebesar 256 pada berat produk tidak sesuai akibat bubuk menggumpal; RPN tertinggi kedua pada biji tidak terpecah 192 disebabkan ukuran biji tidak seragam yang diayak pada ayakan dengan kemiringan lebih dari 40° sementara biji utuh hhasil roasting akibat tidak terpecah memiliki RPN 120. Metode FTA mengidentifikasi penyebab paling dasar dari kedua penyimpangan sehingga dapat ditentukan perbaikan yang tepat. Usulan perbaikan antara lain penegasan dan pemberlakuan SOP pada tiap stasiun kerja khususnya proses sortasi, pencampuran bahan, penyimpanan, dan pengemasan; peningkatan pengawasan oleh pemilik usaha atau pekerja khusus, pengaturan ulang tingkat kemiringan bidang sortasi tidak lebih dari 30o, penambahan ember plastik sebanyak 1-2 buah untuk tiap varian sebagai wadah penyimpanan, serta pelaksanaan briefing setiap pagi sebelum proses produksi berlangsung.
English Abstract
Cocoa plays an important role in Indonesia with a total production of 728,046 tons per year 2021 (Ditjenbun, 2021). One of the cocoa bean derivative products is cocoa powder which is considered healthy for the body because of its polyphenol content. Kelompok Tani Mulyo Jati produces processed cocoa products including cocoa powder. Still often irregularities were found, such as beans not splitting during bean splitting, foreign beans or impurities found in the roasting results, incorrect final product weight, and torn packaging. The cause of the problem needs to be identified and a solution to be found. The purpose of this research is to identify the dominant deviation, the cause of each type of deviation and to design a proposed improvement. The methods in this research are Six Sigma, Failure Mode and Effect Analysis and Fault Tree Analysis. The Six Sigma plays a role in minimizing variations in the entire process with the DMAI concept (Define, Measure, Analyze and Improve). This method is integrated with FMEA to identify opportunities for failure during the production process. The cause of the dominant failure that has a large impact will be known through the highest RPN. In addition to In designing improvement proposals, FTA is used to find out the causes of failure in detail from the most basic failures, so that the suggestions given can be appropriate and are expected to be able to overcome the causes of deviations. The results of the analysis showed that there were three types of dominant deviations in cocoa powder production, namely incompletely split beans, roasted whole beans and variants of cocoa powder products dark, milk and hazelnut did not match. The process of breaking beans, roasting, and packaging the Kelompok Tani Mulyo Jati has a sigma value of 3.05; 4.57; and 3.29 which indicates that cocoa powder production is still competitive in the Indonesian food industry. The FMEA method was developed to determine the priority of the dominant deviation with the highest ranking result in the calculation of the RPN of 256 at an inappropriate product weight due to agglomeration of the powder; The second highest RPN for unsplit seeds was 192 due to non-uniform grain size sifted on a sieve with a slope of more than 40 while whole beans roasted due to not splitting have a RPN of 120. The FTA method identified the most basic cause of the two deviations so that appropriate improvements could be determined. Suggestions for improvement include affirmation and application of SOPs at each work station, especially the sorting process, material mixing, storage, and packaging; increased supervision by business owners or special workers, resetting the level of the sorting field to no more than 30o, adding 1-2 plastic buckets for each variant as storage containers, as well as holding briefings every morning before the production process takes place.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0522100296 |
| Uncontrolled Keywords: | Failure Mode and Effect Analysis, Fault Tree Analysis, Cokelat bubuk, Pengendalian Kualitas, Six Sigma,Failure Mode and Effect Analysis, Fault Tree Analysis, Cocoa Powder, Quality Control, Six Sigma |
| Subjects: | 300 Social sciences > 338 Production > 338.1 Agriculture > 338.16 Production efficiency |
| Divisions: | Fakultas Teknologi Pertanian > Teknologi Industri Pertanian |
| Depositing User: | soegeng sugeng |
| Date Deposited: | 03 Jan 2023 06:34 |
| Last Modified: | 03 Jan 2023 06:35 |
| URI: | http://repository.ub.ac.id/id/eprint/196551 |
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