KAJIAN PENINGKATAN KUALITAS PRODUK UNTUK MENGURANGI REJECT SEAT RING EX TERBALIK PADA PART CYLINDER HEAD DENGAN METODE PDCA DI INDUSTRI OTOMOTIF RODA DUA

Malik, Irvan (2024) KAJIAN PENINGKATAN KUALITAS PRODUK UNTUK MENGURANGI REJECT SEAT RING EX TERBALIK PADA PART CYLINDER HEAD DENGAN METODE PDCA DI INDUSTRI OTOMOTIF RODA DUA. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Kualitas produk merupakan salah satu faktor penentu keberhasilan suatu perusahaan dalam memproduksi barang. PT. XYZ merupakan salah satu perusahan industri manufaktur otomotif mengalami masalah pada kualitas produk. Salah satunya ialah meningkatnya reject cylinder head pda proses assembly seat ring & guide valve. Berdasarkan data reject machining bulan Juni-September 2023 didapatkan jumlah reject seat ring ex terbalik mencapai 46 part. Hal ini disebabkan oleh proses persiapan material yang tidak maksimal sehingga posisi material yang terbalik masuk kedalam proses assembly. Oleh karena itu perlu dilakukan analisa masalah dan perbaikan untuk meminimalisir masalah pada proses produksi. Penelitian ini menerapkan metode PDCA sebagai pendekatan manajemen perbaikan berkelanjutan. Hasil dari pencarian akar masalah menggunakan tools 4M+1E, fishbone Ishikawa chart, dan 5 Why’s Analysis, menemukan bahwa penyebab terjadinya reject adalah pengaturan frekuensi getaran pada mesin rotary feeder yang tidak maksimal. Perbaikan dilakukan pada mesin assembly seat ring dan guide valve dengan melakukan pembersihan stopper pada area mesin, penambahan stopper alternatif, dan mengatur frekuensi getaran. Setelah dilakukan evaluasi, pembersihan stopper mampu mengurangi reject dari 5 part menjadi 3 part. Penambahan stopper alternatif menaikkan kasus reject dari 3 part menjadi 4 part. Pengaturan frekuensi getaran merupakan langkah paling efektif karena mampu mengurangi reject sebanyak 22 part menjadi 0 part. Proses standarisasi yang dilakukan yaitu dengan menambahkan parameter operasi berupa attention point dan penambahan poin pengecekan pada lembar preverentive maintanance.
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Product quality is one of the factors that determine the success of a company in producing goods. PT XYZ is one of the automotive manufacturing industry companies experiencing problems in product quality. One of them is the increasing reject cylinder head in the seat ring & guide valve assembly process. Based on the machining reject data for June-September 2023, the number of reject seat ring ex inverted reached 46 parts. This is caused by the material preparation process that is not maximized so that the inverted position of the material enters the assembly process. Therefore, it is necessary to analyze problems and improvements to minimize problems in the production process. This research applies the PDCA method as a continuous improvement management approach.Result based on the root cause of the problem using 4M+1E tools, fishbone Ishikawa chart, and 5 Why's Analysis, the cause of the reject is the vibration frequency setting on the rotary feeder machine which is not optimal. Improvements were made to the seat ring and guide valve assembly machine by cleaning the stopper in the machine area, adding an alternative stopper, and adjusting the vibration frequency. After evaluation, stopper cleaning was able to reduce rejects from 5 parts to 3 parts. The addition of alternative stopper increased the reject cases from 3 parts to 4 parts. Adjusting the vibration frequency is the most effective measure because it can reduce rejects from 22 parts to 0 parts. The new work standardization process carried out is by adding operating parameters in the form of attention points and additional checking points on the preventive maintenance sheet.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	PDCA, Reject, Machining, Root Cause Analysis, 5 Why’s Analysis PDCA, Reject, Machining, Root Cause Analysis, 5 Why’s Analysis
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	IRVAN MAULANA MALIK
Date Deposited:	07 Aug 2024 02:29
Last Modified:	07 Aug 2024 02:29
URI:	http://repository.its.ac.id/id/eprint/112765

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