Quality Control Analysis and Proposed Alternative Solution for Main Stand Using Six Sigma Method

Mahesa, Rifqi Arya (2024) Quality Control Analysis and Proposed Alternative Solution for Main Stand Using Six Sigma Method. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pertumbuhan ekonomi Indonesia yang kuat telah menyebabkan lonjakan permintaan sepeda motor sebagai moda transportasi utama. PT Automotive merupakan perusahaan yang bergerak di bidang industri komponen sepeda motor, yaitu main stand dan side stand. Seiring dengan meningkatnya jumlah produksi, PT Automotive menghadapi tantangan dalam menjaga kualitas main stand dan side stand, dimana masih terdapat kecacatan yang terjadi pada hasil produksi stand motor yaitu Main Stand K59A/K2VG. Main stand K59A/K2VG memiliki tingkat kecacatan tertinggi yaitu sebesar 0,92% dari total semua periode yang disebabkan oleh cacat rough collar, grounding, spatter, dan painting. Untuk mengatasi masalah tersebut akan dilakukan pengendalian kualitas dengan menggunakan metode six sigma dengan tahap define mengidentifikasi cacat untuk menemukan critical to quality dengan menggunakan diagram pareto dan memetakan aliran proses produksi dengan menggunakan operation process chart. Tahap measure menentukan pengukuran kinerja awal menggunakan metrik DPMO dan level sigma. Tahap analyze menganalisis cacat kritis dan menemukan akar penyebab masalah dengan menggunakan 5 why's. Tahap improve membuat alternatif perbaikan FMEA berdasarkan prioritas akar masalah, validasi perbaikan, dan evaluasi aspek finansial. Pada tahap control akan diberikan instruksi kerja agar alternatif solusi dapat berjalan sesuai dengan yang diinginkan. Dari hasil perhitungan menggunakan diagram Pareto, diketahui bahwa 80% masalah disebabkan oleh grounding, rough collar dan spatter yang merupakan cacat Critical to Quality. Dari hasil analisis menggunakan 5 why, diketahui bahwa terdapat 6 akar permasalahan yang menyebabkan cacat grounding, 3 akar permasalahan yang menyebabkan cacat rough collar dan spatter. Hasil FMEA menunjukkan prioritas akar penyebab yang akan diimprovisasi untuk mengurangi cacat pada Critical to Quality. Untuk cacat grounding dirancang jig inspeksi baru, untuk cacat rough collar dibuat jadwal perawatan baru dengan mempertimbangkan siklus produksi, dan untuk cacat spatter dilakukan revisi instruksi kerja. Proses validasi yang melibatkan wawancara dengan kepala produksi di PT Automotive menemukan bahwa 50% cacat dapat dikurangi dengan alternatif ini yang membawa tingkat sigma menjadi 4,5, naik dari kondisi saat ini yaitu 4,28. Validasi finansial menunjukkan bahwa alternatif ini memenuhi kriteria investasi yang menguntungkan.

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Indonesia's strong economic growth has led to a surge in demand for motorbikes as the main mode of transportation. PT Automotive is a company that operates in the motorbike component industry, namely main stands and side stands. Along with increasing production numbers, PT Automotive faces challenges in maintaining the quality of main stands and side stands, where there are still defects that occur in the production of motorbike stands, namely Main Stand K59A/K2VG. Main stand K59A/K2VG has the highest defect rate of 0.92% of the total of all periods caused by rough collar, grounding, spatter, and painting defects. To overcome this problem, quality control will be carried out using the six sigma method with the define stage identifying defects to find critical to quality using a Pareto chart and mapping the production process flow using an operation process chart. The measure stage determined baseline performance measurements using DPMO metrics and sigma levels. The analyze stage analyzed critical defects and found the root cause of the problem using the 5 why's. The improve stage created alternative FMEA improvements based on root cause priorities, validation of improvements, and evaluation of financial aspects. In the control stage, work instructions will be given so that alternative solutions can run as desired. From the calculation using Pareto diagram, it is known that 80% of the problems are caused by grounding, rough collar and spatter which are Critical to Quality defects. From the analysis using 5whys, it is known that there are 6 root causes that caused grounding defects, 3 root causes that caused rough collar and spatter defects. The FMEA results show the priority of root causes that will be improvised to reduce defects in Critical to Quality. For the grounding defect designed a new inspection jig, for the collar defect created a new maintenance schedule considering the production cycle, and for the spatter defect revised work instructions. The validation process involving interviews with head production at PT Automotive found that 50% of defects can be reduced with this alternative which brings the sigma level to 4.5, up from the current condition of 4.28. Financial validation showed that this alternative meets the criteria of a profitable investment.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Six Sigma, DMAIC, Defect, Sigma Value, Root Cause Analysis, FMEA, Jig and Fixture
Subjects:	T Technology > T Technology (General) > T57.5 Data Processing T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > T Technology (General) > T59.7 Human-machine systems. T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Rifqi Arya Mahesa
Date Deposited:	08 Feb 2024 06:59
Last Modified:	08 Feb 2024 06:59
URI:	http://repository.its.ac.id/id/eprint/106418

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