Usulan Perbaikan Pada Proses Produksi Pembuatan Aki Hybrid Dengan Pendekatan Lean Six Sigma (Studi Kasus UD. XYZ)

Farida, Siti (2022) Usulan Perbaikan Pada Proses Produksi Pembuatan Aki Hybrid Dengan Pendekatan Lean Six Sigma (Studi Kasus UD. XYZ). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

UD. XYZ merupakan pelaku bisnis informal pada sektor industri aki mobil dengan produk berupa aki hybrid. Saat ini UD. XYZ telah memiliki 9 tipe aki hybrid yaitu NS 40, NS 40Z, NS. 40 ZL, N. 50, N. 50Z, NS. 70, NS. 60, NS. 60L, dan NS. 60S dengan produk utama yaitu aki hybrid tipe NS. 70. Terdapat permasalahan tentang pemborosan berdasarkan E-DOWNTIME waste yang menimbulkan potensi kerugian bagi UD. XYZ. Penelitian bertujuan memperbaiki proses produksi di UD. XYZ menjadi lebih ramping, namun tetap memperhatikan kualitas dengan menggunakan Lean Six Sigma. Penelitian mengikuti kerangka DMAIC (Define, Measure, Analyze, Improve, dan Control). Perbaikan difokuskan pada waste kritis dengan kriteria pemilihan waste kritis berdasarkan potensi kerugian akibat adanya pemborosan dan waste dengan sigma level di bawah 2 σ. Didapatkan 3 waste kritis dengan total 6 subwaste. Hasil measure pada sigma level awal waste kritis yaitu pada EHS-subwaste risiko potensial di lingkungan fisik kerja 3 σ, EHS-subwaste ketidaksesuaian APD 2,74 σ, defect-subwaste peleburan ulang timah 2,55 σ, defect-subwate kisi patah pinggir 2,51 σ, defect-subwaste pembongkaran aki rusak 3,07 σ, serta waiting-subwaste kejadian overcharging yang disertai defect 0,66 σ. Pada waste kritis dilakukan analisis menggunakan 5 Why’s dan penilaian risiko sehingga didapatkan dari 20 root cause ada 9 root cause yang diprioritaskan untuk proses improvement. Improvement pada aspek K3, perbaikan pada proses casting kisi positif, serta perbaikan pada proses filling dan formation dilakukan dengan memberikan rekomendasi bahan tambahan, peralatan, pengaman terhadap kondisi kerja, metode kerja, ataupun kontrol yang diharapkan dapat memperbaiki proses produksi di UD. XYZ sekaligus meningkatkan safety. Alternatif solusi dengan membuat panduan dan checksheet kontrol juga dilakukan agar target perbaikan dapat dicapai dan dipertahankan. Penerapan rekomendasi perbaikan ditargetkan dapat menurunkan potensi kerugian akibat waste dan terjadi peningkatan level sigma dari masing-masing subwaste yaitu menjadi 3,83 σ; 3,88 σ; 2,76 σ; 3,03 σ; 3,65 σ; dan 2,12 σ.
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Sole proprietorship (SP) XYZ is an informal company that engage in the lead acid battery car industry with a product in the form of a hybrid battery. Currently SP. XYZ already has 9 types of hybrid batteries, namely NS. 40, NS. 40Z, NS. 40 ZL, N. 50, N. 50Z, NS. 70, NS. 60, NS 60L, and NS. 60S with the main product being the NS. 70 type hybrid battery. There is a problem based on E-DOWNTIME waste that could cause potential losses for SP. XYZ. The research aims to improve the production process in SP. XYZ becomes leaner, but still concern about the quality by using Lean Six Sigma. The research followed the DMAIC framework (Define, Measure, Analyze, Improve, and Control). Improvements to critical waste with critical selection based on potential losses due to waste and waste with a sigma level below 2 σ. 3 critical waste with a total of 6 subwaste are obtained. The measurement results at the initial level of critical waste are EHS-subwaste risk potential in the physical work environment 3 σ, EHS-subwaste PPE mismatch 2,74 σ, lead re-smelting defect-subwaste 2,55 σ, lattice defect-subwate fractured edges 2,51 σ, the defect-subwaste for dismantling the damaged battery was 3,07 σ, and the waiting-subwaste for the occurrence of overcharging accompanied by a defect of 0,66 σ. In wastage, 5 Why's analysis and risk assessment were carried out so that from 20 root causes there were 9 root causes that were prioritized for the improvement process. Improvements to the EHS aspect, improvements to the positive lattice casting process, as well as improvements to the filling and forming process are carried out by providing recommendations for additional materials, equipment, safety for working conditions, work methods, or controls that are expected to improve the production process while increasing the safety. Alternative solutions by making guidelines and control check sheets were also carried out so that the improvement targets could be achieved and maintained. The implementation of improvement recommendations can reduce potential losses due to waste and increase the sigma level of each sub-waste to 3,83 σ ; 3,88 σ; 2,76 σ; 3,03 σ; 3,65 σ; and 2,12 σ.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Penilaian Risiko, Lean Six Sigma, Lead Acid Hybrid Battery, DMAIC, E-DOWNTIME Waste, Risk Assessment, Lean Six Sigma
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	22 Jan 2026 04:02
Last Modified:	22 Jan 2026 04:02
URI:	http://repository.its.ac.id/id/eprint/130073

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