Implementation of Six Sigma DMAIC Method in Minimizing Defect and Increasing Production Capacity of Upih Tray 750 ML in Plepah Indonesia

Dzakir, Rafi Muhammad (2023) Implementation of Six Sigma DMAIC Method in Minimizing Defect and Increasing Production Capacity of Upih Tray 750 ML in Plepah Indonesia. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Plepah Indonesia adalah industri kemasan makanan ramah lingkungan. Plepah Indonesia memiliki 3 produk: Upih Tray 750 ml, Upih Tray 1500 ml, dan Upih 4 kompartemen. Proporsi cacat untuk Upih Tray 750 ml, Upih Tray 1500 ml, dan Upih 4 kompartemen masing-masing adalah 8,9%, 6,4%, dan 6,5%. Oleh karena itu, fokus utama berada pada Upih Tray 750 ml karena memiliki proporsi cacat tertinggi. Terdapat 7 jenis cacat. Selanjutnya, CTQ (Critical to Quality) adalah jenis cacat kritis yang dipilih dan diidentifikasi berdasarkan prinsip Pareto (80/20) dari 7 jenis cacat. Berdasarkan perhitungan dalam Pareto Chart, jenis cacat CTQ adalah retak, berlubang, dan pemotongan yang tidak sempurna. Semua cacat ini menyebabkan kerugian pendapatan sekitar IDR 1.428.000 untuk Plepah Indonesia pada bulan Februari 2023. Oleh karena itu, perbaikan harus dilakukan untuk meminimalkan cacat dan meningkatkan kapasitas produksi Upih Tray 750 ml. Six Sigma DMAIC, Pareto Chart, Critical to Quality (CTQ), Value Stream Mapping, 5 Whys, Operation Process Chart, dan Failure Mode Effect Analysis (FMEA) adalah alat/kerangka kerja yang digunakan untuk mencapai tujuan tersebut. Pada tahap "define", langkah-langkahnya adalah mengidentifikasi proses produksi dan mengidentifikasi cacat produk serta kapasitas produksi Upih Tray 750 ml. DPMO dan tingkat sigma akan dihitung pada tahap "measure". Pada tahap "analyze", CTQ dan penyebab cacat saat ini akan dianalisis menggunakan analisis akar penyebab 5 Whys dan FMEA untuk mendapatkan hasil akar penyebab kritis dari RPN (Risk Priority Number) tertinggi. Akhirnya, pada tahap "improvement", disajikan saran alternatif untuk meminimalkan cacat dan meningkatkan kapasitas produksi. Terdapat 3 perbaikan alternatif. Setelah perbaikan alternatif terbaik dipilih, nilai sigma meningkat dari 3,26 menjadi 3,53. Selain itu, kapasitas produksi meningkat dari 2043 unit dalam kondisi eksisting menjadi 2066 unit dalam kondisi yang diperbaiki.
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Plepah Indonesia is an environmental food packaging industry. Plepah Indonesia has 3 products: Upih Tray 750 ml, Upih Tray 1500 ml, and Upih 4 compartment. The defect proportion for Upih Tray 750 ml, Upih Tray 1500 ml, and Upih 4 compartment respectively are 8.9%, 6.4%, and 6.5%. Therefore, the main focus is on Upih Tray 750ml due to the highest defect proportion. There are 7 types of defects. Furthermore, CTQ is the chosen critical defect type and is identified based on the Pareto principle (80/20) of the 7 defects type Based on the calculation in Pareto Chart, the CTQ defect are cracked, perforated, and imperfect cutting. All of these defects cause a revenue loss for Plepah Indonesia of about IDR 1,428,000 on February 2023. Therefore, improvements should be done to minimize defects and increase the production capacity of Upih Tray 750 ml. Six Sigma DMAIC, Pareto Chart, Critical to Quality (CTQ), Value Stream Mapping, 5 Whys, Operation Process Chart, and Failure Mode Effect Analysis (FMEA) is the tool/framework used to achieve those objectives. In the define phase, the steps are identifying the production process and identifying product defects & production capacity of Upih Tray 750ml. DPMO and sigma levels will be calculated in the measure phase. In analyze phase, the CTQ and current causes of defects will be analysed using 5 whys root cause analysis and FMEA to get the result of critical root cause from the highest RPN. Finally, the improvement phase presents an alternative suggestion to minimize defects and increase production capacity. There are 3 alternative improvements. After the best alternative improvement is chosen. the sigma value increased from 3.26 to 3.53. Furthermore, the production capacity increased from 2043 units in the existing condition to 2066 units in the improved condition.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Six Sigma DMAIC, Cacat, Nilai Value, Kapasitas Produksi, Perbaikan Alternatif, Upih Tray 750ml ============================================================ Six Sigma DMAIC, Defect, Sigma Value, Production Capacity, Alternative Improvement, Upih Tray 750ml
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Rafi Muhammad Dzakir
Date Deposited:	03 Aug 2023 03:56
Last Modified:	03 Aug 2023 03:56
URI:	http://repository.its.ac.id/id/eprint/100505

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