Pengembangan Kerangka Kerja Zero-Defect Manufacturing untuk Industri Makanan. Studi Kasus: Pembentukan Busa pada Proses Pengisian Susu Pasteurisasi

Choirussabila, Arifni (2025) Pengembangan Kerangka Kerja Zero-Defect Manufacturing untuk Industri Makanan. Studi Kasus: Pembentukan Busa pada Proses Pengisian Susu Pasteurisasi. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pembentukan busa pada susu adalah fenomena yang umum diamati, namun penelitian tentang pembentukan busa selama proses pengisian susu ke dalam kemasan karton 1 liter masih sangat terbatas. Salah satu masalah utama yang dihadapi produsen susu adalah kesulitan dalam melakukan inspeksi busa pada kemasan tertutup, sehingga menjadi motivasi untuk membuat eksperimen sebagai pencegahan pembentukan busa. Penelitian ini mengusulkan kerangka kerja Zero-Defect Manufacturing (ZDM) untuk industri makanan dengan strategi pencegahan untuk mengatasi pembentukan busa selama proses pengisian susu. Melalui Focus Group Discussion (FGD) bersama dengan stakeholder, diidentifikasi tujuh faktor penyebab terbentuknya busa selama proses pengisian susu, yaitu kandungan protein, kandungan lemak, kecepatan pengisian, suhu produk, tekanan supply, level kecepatan agitator, dan skema produksi. Dataset sebanyak 2197 dianalisis menggunakan plaform No-Code Artificial Intelligence (NCAI), yaitu CreateML, Obviously AI, dan Graphite Note untuk mengevaluasi keterkaitan antara parameter proses dan kemungkinan terbentuknya busa. Variabel input yang paling berpengaruh adalah kecepatan pengisian (76%) dan kandungan protein 23%. Rekomendasi intervensi parameter pemrosesan meliputi penyesuaian kecepatan pengisian pada rentang 75-80%, suhu produk pada rentang 5-6˚C, serta tekanan supply <1.5 bar. Hasil intervensi pada 10 batch produksi menunjukkan hasil positif yaitu speed reduction impact index relatif sama dengan baseline, dengan peningkatan sebesar 0.82%, serta penurunan kejadian busa (75%), down time untuk mengatasi busa (77%), reprocess dan repacking (62%), serta cost of non conformance (73%). Kerangka kerja ini dinilai relevan untuk diterapkan dan perlu diuji lebih lanjut dalam konteks industri yang lain.
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The foam formation in milk is a relatively common observed phenomenon. However, there has been limited research on foam formation during milk filling into 1-litre cartons. One of the main problems faced by dairy producers is the difficulty in inspecting foam in non-transparent packages, which motivated the experiment to prevent foam formation. Consequently, this study proposes a new approach by proposing a Zero-Defect Manufacturing (ZDM) framework for the food industry with prevention strategies to address the foam formation during the milk filling process. Through a focus group discussion with stakeholders, seven factors causing foam formation during the milk filling process were identified, including protein content, fat content, filling speed, product temperature, supply pressure, agitator status, and production scheme. Furthermore, a dataset of 2197 rows was analyzed on three No-Code Artificial Intelligence (NCAI) platforms, including CreateML, Obviously AI, and Graphite Note platforms to evaluate the relationship between process parameters and the likelihood of foam formation. The key drivers of input variables were filling speed (76%) and protein content (23%). Intervention recommendations for processing parameters include adjusting the filling speed in the range of 75-80%, product temperature in the range of 5-6˚C, and supply pressure <1.5 bar. The intervention results on 10 production batches showed positive results, the speed reduction impact index was relatively the same as baseline, with increase of 0.82%, and a decrease in foam formation (75%), downtime to address foam (77%), reprocessing and repacking (62%), and the cost of non conformance (73%). This framework is considered relevant for implementation and needs to be further tested in other industrial contexts.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Dairy, Filling Process, Foam, Food Industry, No-Code Artificial Intelligence, Pasteurized Milk, Quality Control, Quality Improvement, Zero-Defect Manufacturing
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Arifni Choirussabila
Date Deposited:	07 Jul 2025 04:22
Last Modified:	07 Jul 2025 04:22
URI:	http://repository.its.ac.id/id/eprint/119391

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