Pengendalian Cacat Produk Kayu Lapis Menggunakan Metode Integrasi Six Sigma Dan Triz

Karim, Imam Syafii (2025) Pengendalian Cacat Produk Kayu Lapis Menggunakan Metode Integrasi Six Sigma Dan Triz. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. XYZ adalah salah satu perusahaan industri kayu lapis yang berlokasi di Banjarmasin, Kalimantan Selatan. Salah satu permasalahan yang dihadapi perusahaan saat ini adalah ketidakstabilan proses produksi sehingga menghasilkan kualitas produk yang tidak stabil, hal ini bisa dilihat dari masih seringnya ditemukan cacat produk berulang di setiap periode proses produksinya. Munculnya produk cacat ini merugikan perusahaan dikarenakan adanya kerja ulang perbaikan produk cacat yang menyebabkan penambahan biaya produksi ataupun turunnya nilai dari produk kayu lapis yang ditemukan cacat. Perusahaan perlu mengupayakan suatu cara yang efektif dan efisien melalui pengendalian kualitas pada tingkat proses untuk mencegah dan mengurangi cacat yang terjadi. Penelitian ini menggunakan metode Six Sigma sebagai landasan proses perbaikan dengan tahapan alur Define, Measure, Analyze, Improve, Control (DMAIC). Tahap Define meliputi pembuatan diagram alir proses dengan diagram SIPOC dan penentuan objek perbaikan dengan diagram batang, di mana didapatkan cacat paling dominan adalah overlap sebesar 28,2%. Pada tahap Measure dilakukan pengukuran baseline kinerja proses berdasarkan data produksi bulan Juli 2022 sampai September 2022 dan diperoleh nilai DPMO sebesar 10.551 dan level Six Sigma senilai 3,81. Selain itu dilakukan pemantauan stabilitas proses dengan control chart dan perhitungan kapabilitas proses didapat nilai Cp sebesar 1,27. Tahap Analyze menggunakan Fishbone Diagram dan FMEA, didapatkan faktor penyebab dominan cacat over laps kayu lapis adalah ketidakkonsistenan dan kecerobohan karyawan dalam penataan veneer serta cara penyusunan veneer yang terlalu cepat. Pada tahap Improve, rekomendasi perbaikan yang diberikan berdasarkan 40 Inventive Principle TRIZ adalah pelatihan, pengawasan dan supervisi tambahan kepada operator untuk peningkatan skill dan awareness, program pengakuan dan reward untuk peningkatan motivasi operator serta kontrol visual pada lem untuk mengendalikan kualitas pelaburan lem pada proses glue spreader.

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PT. XYZ is a plywood manufacturing company located in Banjarmasin, South Kalimantan. One of the company's current challenges is production process instability, resulting in inconsistent product quality. This is evident in the frequent recurrence of product defects throughout the production process. These defects are detrimental to the company due to rework and repair, leading to increased production costs and reduced value of the defective plywood products. The company needs an effective and efficient method for process-level quality control to prevent and reduce defects. This research utilizes the Six Sigma methodology with the Define, Measure, Analyze, Improve, Control (DMAIC) framework for process improvement. The Define phase involved creating a process flow diagram using a SIPOC diagram and identifying improvement objectives using a bar chart, which revealed that the most dominant defect was overlap at 28.2%. The Measure phase involved measuring baseline process performance based on production data from July to September 2022, resulting in a DPMO of 10,551 and a Six Sigma level of 3.81. Process stability was monitored using control charts, and process capability analysis yielded a Cp value of 1.27. The Analyze phase employed a Fishbone diagram and FMEA, identifying inconsistent and careless veneer arrangement and excessively fast veneer stacking by employees as the dominant causes of plywood overlap defects. In the Improve phase, improvement recommendations based on the 40 Inventive Principles of TRIZ include additional training, supervision, and oversight for operators to enhance skills and awareness; a recognition and reward program to boost operator motivation; and visual controls for glue to manage glue application quality in the glue spreader process.

Keywords: Product Defect, Plywood, Six Sigma, TRIZ

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Cacat Produk, Kayu Lapis, Six Sigma, TRIZ, Product Defect, Plywood
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control)
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Imam Syafii Karim
Date Deposited:	02 Feb 2025 07:04
Last Modified:	02 Feb 2025 07:04
URI:	http://repository.its.ac.id/id/eprint/117694

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