Izzaturobby, Muhammad Hawary (2017) Upaya Reduksi Waste pada Proses Produksi Side Body Mobil APV-Van Menggunakan Metode Lean-Six Sigma. Sarjana thesis, Universitas Brawijaya.
Abstract
PT. Suzuki Indomobil Motor Plant II merupakan salah satu bagian dari perusahaan Suzuki Group dimana bergerak dalam industri manufaktur yang memproduksi kendaraan roda empat. Produknya antara lain adalah Carry, APV-Truck, APV-Van, dan Karimun. Dari keempat mobil yang diproduksi, APV-Van memiliki defect yang tertinggi dibandingkan dengan produk lain, dimana dalam lini produksi APV-Van, workstation Side Body APV-Van memiliki waste yang dominan dibandingkan dengan workstation lainnya. Permasalahan waste pada workstation Side Body APV-Van, antara lain adalah defect dan waiting, sehingga memerlukan tindakan solutif untuk mengatasi permasalahan tersebut. Dengan demikian, tujuan penelitian ini adalah mengidentifikasi macam-macam waste dan waste dominan pada proses produksi Side Body APV-Van, serta memberikan rekomendasi perbaikan untuk mereduksi waste dominan tersebut. Tahapan dalam penelitian ini dimulai dengan penelitian pendahuluan yang terdiri dari studi lapangan, studi literatur, identifikasi masalah, dan penentuan tujuan penelitian. Tahap selanjutnya adalah pengumpulan data yang berupa data primer dan data sekunder. Tahap berikutnya adalah pengolahan data yang dilakukan dari fase define menggunakan Stopwatch Time Study, Operation Process Chart dan Flow Process Chart, serta mengklasifikasikan seven waste. Fase selanjutnya adalah measure, untuk mendapatkan critical to quality dan level sigma. Selanjutnya pada fase analyze dengan menggunakan cause and effect diagram dan Failure Mode and Effect Analysis. Serta pada fase improve dilakukan rancangan perbaikan untuk mereduksi waste yang ada. Tahapan selanjutnya adalah melakukan analisis dan pembahasan terhadap penelitian yang telah dilakukan. Lalu tahapan terakhir dengan melakukan penarikan kesimpulan dan saran. Hasil penelitian ini berupa pengidentifikasian waste pada workstation Side Body APVVan, berdasarkan hasil identifikasi diketahui waste defect sebesar 56,40%, waste waiting sebesar 13,93%, waste unnecessary inventory sebesar 11,97%, waste overproduction sebesar 10,47%, waste transportation sebesar 7,23%, sedangkan waste unnecessary motion dan overprocessing tidak dianggap waste di workstation Side Body APV-Van. Dari ketujuh waste, 80% waste yang dominan adalah waste defect, waste waiting, dan waste unnecessary inventory. Sedangkan rekomendasi perbaikan yang diberikan untuk mengurangi ketiga waste tersebut diantaranya adalah pemberian pokayoke, dan pemberian instruksi dalam melakukan proses spot welding & setting sensor, serta standar operating procedure dalam melakukan inspeksi posisi & kondisi jig.
English Abstract
PT. Indomobil Suzuki Motor Plant II is a part of Suzuki Group company, which is concerned in automobile manufacturing industry producing four-wheeled vehicles. Its products include the Carry, APV-Van, APV-Truck, and Karimun. From the four cars produced, APV-Van has the highest defects compared to other products, where the production line in the APV-Van, the workstation Side-Body APV-Van has higher waste compared to other workstations. The problem of waste on the workstation Side-Body APV-Van, are defects and waiting, so it take a solutional actions to solve these problems. Thus, the purpose of this research is to identify the various waste and waste production process on the dominant Side Body APV-Van, as well and to provide recommendations for improvement to the reduction of waste is dominant. Steps during this research is started with the preliminary research that comprises the field study, the literature study, problem identification, and determination of the research objectives. The next step is the collection of data in the form of primary data and secondary data. The first phase is the define phase, which uses Stopwatch Time Study, Operation Process Charts and Flow Process Chart, and alse classifying the seven wastes. The next phase is to measure, to obtain the critical to quality and sigma levels. The next phase is analyzing by using cause and effect diagrams and Failure Mode and Effect Analysis. The next phase is improve, make an improvement draft to reduce waste. Aftewards, analysis and discussion against the research that will be done. The last stage is to withdraw with the conclusions and suggestions. The results of this research is waste identification at the Side-Body APV-Van workstation, based on the results of the identification the amount of defects waste was about 56.40%, waiting waste was about 13.93%, unnecessary inventory waste was about 11.97%, overproduction waste was about 10.47%, waste transportation was about 7.23%, while waste unnecessary motion and over processing wasn’t considered a waste on the workstation Side-Body APV-Van. From all of the seventh wastes, 80% of the dominant waste is defects waste, waiting waste, and unnecessary inventory waste. The improvements recommendations given to reduce the waste are pokayoke systems, and giving instructions in the process of spot welding & sensors setting, as well as giving standard operating procedure in the process of potition inspection & jig conditions.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2017/889/051708732 |
| Uncontrolled Keywords: | Failure Mode and Effect Analysis, Lean-Six Sigma, Side Body APV-Van, Seven Wastes, Stopwatch Time Study. |
| Subjects: | 600 Technology (Applied sciences) > 658 General management > 658.5 Management of production > 658.56 Product control, packaging; waste control and utilization > 658.562 Quality control |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Budi Wahyono Wahyono |
| Date Deposited: | 15 Sep 2017 02:21 |
| Last Modified: | 22 Oct 2020 04:59 |
| URI: | http://repository.ub.ac.id/id/eprint/2561 |
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