Penerapan Lean Six Sigma untuk Mengurangi Pemborosan dan Meningkatkan Kualitas Produksi Drum Aspal

Saputri, Tania Anggi (2025) Penerapan Lean Six Sigma untuk Mengurangi Pemborosan dan Meningkatkan Kualitas Produksi Drum Aspal. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Di era kompetitif saat ini, perusahaan dituntut untuk meningkatkan efektivitas produksi dengan mengurangi pemborosan serta menjaga manajemen kualitas guna mempertahankan eksistensinya. Namun, hal ini belum diimplementasikan secara optimal di BPG (Bitumen Plant Gresik), sebuah unit bisnis distribusi aspal di Indonesia, yang masih menghadapi permasalahan pemborosan waktu proses dan kecacatan dalam proses fabrikasi drum aspal. Berdasarkan data tahun 2024, persentase reject mencapai 11,16% dari total produksi 555.070 unit, dengan estimasi kerugian sebesar Rp777.711.482. Nilai DPMO (Defect per Million Opportunities) tercatat sebesar 20.166,67 dan tingkat sigma hanya sebesar 3,5, menandakan bahwa proses masih jauh dari standar kualitas. Selain itu, hasil pemetaan Value Stream Mapping (VSM) menunjukkan total lead time produksi drum sebesar 3.891,05 menit, dengan hanya 75,60% berupa value added activity (VA). Penelitian ini bertujuan mengidentifikasi critical waste, menganalisis akar penyebab, merancang usulan perbaikan, meningkatkan sigma level, dan menurunkan potential loss. Pendekatan Lean Six Sigma (LSS) digunakan melalui kerangka DMAIC (Define, Measure, Analyze, Improve, Control) dan alat bantu perbaikan lainnya. Beberapa tindakan korektif yang dilakukan meliputi perubahan standar pengecekan material masuk, implementasi jadwal perawatan mesin, pembuatan SOP, serta perbaikan tata letak fasilitas produksi. Setelah implementasi perbaikan, nilai VA meningkat dari 2.880,2 menjadi 2.941,93 menit, nilai sigma naik menjadi 4,04 dan DPMO turun menjadi 6.210. Peningkatan process cycle efficiency (PCE) tercatat menjadi 76,66%, serta potential loss berhasil ditekan sebesar 38% antara Januari–Februari dan Maret–April 2025.
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In today’s competitive era, companies are required to improve production effectiveness by reducing waste and maintaining quality management in order to sustain their
existence. However, this has not been optimally implemented at Bitumen Plant Gresik (BPG), an asphalt distribution business unit in Indonesia, which continues to face issues
related to process time wastage and defects in the asphalt drum fabrication process. Based on 2024 data, the reject rate reached 11.16% out of a total production of 555,070
units, with an estimated financial loss of IDR 777,711,482. The Defect per Million Opportunities (DPMO) was recorded at 20.166,67 with a sigma level of only 3.5, indicating that the process remains far from the desired quality standards. Furthermore, results from the Value Stream Mapping (VSM) indicate a total production lead time of 3,891.05 minutes, with only 75.60% classified as value-added activity (VA). This study aims to identify the critical waste, analyze root causes, design improvement proposals, increase the sigma level, and reduce potential losses. The Lean Six Sigma (LSS) approach was employed through the DMAIC (Define, Measure, Analyze, Improve, Control) framework, along with other improvement tools. Several corrective actions were implemented, including revising the standard for incoming material inspection, establishing a machine maintenance schedule, developing standard operating procedures (SOPs), and optimizing the layout of the production facility. Following the improvements, the VA increased from 2,880.2 to 2,941.93 minutes, the sigma level rose to 4.04, and the
DPMO decreased to 6,210. Process Cycle Efficiency (PCE) improved to 76.66%, and the potential loss was successfully reduced by 38% between the January–February and March–April 2025 periods.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Lean Six Sigma, DMAIC, DPMO, Tingkat Sigma, Value Stream Mapping, dan Critical to Quality. Lean Six Sigma, DMAIC, Sigma Level, Value Stream Mapping, and Critical to Quality
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD62.15 Total quality management. T Technology > TS Manufactures 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:	Tania Anggi Saputri
Date Deposited:	10 Jul 2025 01:23
Last Modified:	10 Jul 2025 01:23
URI:	http://repository.its.ac.id/id/eprint/119440

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