Priyambodo, Daffa (2022) Penerapan Lean Six Sigma Dalam Pembuatan Kereta KKBW 480 5T Dengan Pembentukan Plat S355JR - TP Pada Cutting Plan Di PT. Industri Kereta Api Persero. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT. Industri Kereta Api merupakan perusahaan BUMN yang bergerak dalam bidang manufaktur dengan berbagai jenis kereta seperti lokomotif, kereta penumpang, kereta berpenggerak, gerbong barang, dan kereta khusus salah satunya kereta KKBW 480 50T untuk mengangkut batubara. Dalam produksi kereta KKBW 480 50T terdapat material waste, hal ini dapat menyebabkan pemborosan dalam pengeluaran biaya oleh perusahaan. Waste dapat didefinisikan sebagai segala aktivitas kerja yang tidak memberikan nilai tambah dalam proses transformasi input menjadi output sepanjang value stream. Pada kasus yang akan dibahas, terdapat permasalahan mengenai material waste berupa SJ355JR – TP dalam produksi kereta KKBW 40 50T. Pada cuttingplan terdapat 3 waste yaitu berupak defect, overprocessing, dan waiting. Waste yang ada pada cuttingplan terdapat crack berjumlah 1 pcs, keropos berjumlah 8 pcs, dan karat berjumlah 19 pcs, maka total dari defect yaitu 28 pcs plat S355JR – TP. Dalam megatasi material waste pada saat produksi, perlu adanya tahapan Six Sigma yakni metode Six Sigma DMAIC. Tahapan pertama Define yaitu tahapan untuk mendefinisikan dan menyeleksi permasalahan yang akan diselesaikan beserta biaya, manfaat, dan dampak terhadap pelanggan (customer), Measurement adalah Tahapan Pengukuran terhadap permasalahan yang telah didefinisikan untuk diselesaikan dengan hasil nilai Sigma yaitu 2,131, Tahapan Analysis adalah tahapan untuk menemukan solusi untuk memecahkan masalah berdasarkan Root Cause Analysis (RCA) (dengan bantuan fishbone dan 5 Why’s), dan Failure Mode and Effect Analysis (FMEA) yang telah di-identikasikan, tahap selanjutnya adalah Improvement yakni melakukan perhitungan Analytical Hierarchy Process (AHP) untuk dapat mengoptimasikan solusi tersebut sehingga benar-benar bermanfaat untuk menyelesaikan permasalahan yang dialami. Hasil dari penelitian ini ditemukan tiga alternatif perbaikan yaitu mengatur jadwal operasional dan inspeksi berkala terhadap mesin, memiliki Standard Operational Procedure (SOP) sesuai dengan keperluan, dan melakukan pelatihan untuk operator terhadap mesin cutting yang dijalankan.
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PT. The Railway Industry is a state-owned company engaged in manufacturing with various types of trains such as locomotives, passenger trains, self-propelled trains, freight cars, and special trains, one of which is the KKBW 480 50T train to transport coal. In the production of the KKBW 480 50T train there is material waste, this can cause waste in spending by the company. Waste can be defined as all work activities that do not provide added value in the process of transforming inputs into outputs along the value stream. In the case to be discussed, there is a problem regarding waste material in the form of SJ355JR – TP in the production of the KKBW 40 50T train. In the cutting plan there are 3 wastes, namely in the form of defects, overprocessing, and waiting. The waste in the cutting plan has 1 pcs of crack, 8 pcs of porous, and 19 pcs of rust, so the total defect is 28 pcs of S355JR – TP plate. In overcoming material waste during production, it is necessary to have a Six Sigma stage, namely the Six Sigma DMAIC method. The first stage is Define, which is the stage to define and select the problems to be solved along with the costs, benefits, and impacts on the customer (customer), Measurement is the Stage of Measurement of the problems that have been defined to be solved with the result of the Sigma value of 2.131, Stages of Analysis is the stage to find solutions to solve problems based on Root Cause Analysis (RCA) (with the help of fishbone and 5 Why's), and Failure Mode and Effect Analysis (FMEA) that have been identified, the next step is Improvement, namely performing Analytical Hierarchy Process (AHP) calculations to be able to optimize the solution so that it is really useful to solve the problems experienced. The results of this study found three alternative improvements, namely setting an operational schedule and periodic inspections of the machine, having a Standard Operational Procedure (SOP) as needed, and conducting training for operators on the cutting machine that is run.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Waste, DMAIC, Six Sigma, RCA, FMEA, AHP |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD56.25 Industrial efficiency--Measurement. Industrial productivity--Measurement. |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | Mr. Marsudiyana - |
| Date Deposited: | 11 Feb 2026 08:57 |
| Last Modified: | 11 Feb 2026 08:57 |
| URI: | http://repository.its.ac.id/id/eprint/132388 |
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