Yuliana, Dita Dwi (2022) Upaya Reduksi Waste Produk Gula Kristal Putih Dengan Pendekatan Lean Six Sigma (Studi Kasus: PG Ngadiredjo Kediri -PT Perkebunan Nusantara X). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Salah satu penyebab baik buruknya produk adalah adanya pengaruh penjaminan kualitas. Dimana perlu dilakukan pengawasan kualitas yang tepat sasaran khususnya pada proses pengolahan sebuah produk. Permasalahan waste menjadi salah satu hal yang sering terjadi pada proses pengolahan, seperti yang dihadapi PG Ngadiredjo yakni masih terjadi waiting dan losses, munculnya defect produk gula kristal, serta terjadinya rework process pada hasil proses produksi yang tidak sesuai standar spesifikasi. Untuk mengurangi permasalahan tersebut, digunakan pendekatan lean six sigma dengan metode Define, Measure, Analyze, Improve, Control (DMAIC), Root Cause Analysis (RCA), Failure Mode and Effect Analysis (FMEA) serta alternatif perbaikan berdasarkan konsep kaizen untuk menghilangkan proses yang tidak menambah nilai dan mengurangi terjadinya variasi yang tidak menguntungkan dalam proses produksi gula kristal putih. Dalam penelitian ini, dilakukan identifikasi waste, akar penyebab terjadinya waste serta pembuatan usulan perbaikan sebagai upaya dalam meningkatkan kualitas produk gula kristal putih pada PG Ngadiredjo Kediri yang merupakan unit pabrik gula PT Perkebunan Nusantara X. Identifikasi waste dilakukan berdasarkan klasifikasi E-DOWNTIME berupa waste berdasarkan environmental, health and safety (EHS); defect; overproduction; waiting; unutilized talent; transportation; inventory; motion; excess processing. Dengan penerapan usulan alternatif perbaikan berupa melakukan inspeksi alat dan cleaning instrument secara rutin; mengadakan pelatihan dan inspeksi kinerja operator serta pembentukan buku panduan dan tim pengawasan safety, didapatkan fakta bahwa terjadi peningkatan level sigma dari masing-masing waste yakni peningkatan level sigma dari 2,51 menjadi 2,94 untuk waiting waste; 2,78 menjadi 3,26 untuk excess processing waste; 3,62 menjadi 4,03 untuk EHS waste; 3,70 menjadi 3,88 untuk inventory waste; 3,74 menjadi 3,98 untuk transportation waste dan 3,94 menjadi 4,18 untuk defect waste. Dengan adanya usulan perbaikan ini, diharapkan dapat mempermudah PG Ngadiredjo dalam mereduksi waste produk gula kristal putih PG Ngadiredjo Kediri.
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One of the causes of good and bad products is influenced by quality assurance according to standard specifications. Where quality control is carried out on target, especially in the processing of a product. The problem of waste or waste is one of the things that affect the processing process such as case in PG Ngadiredjo, where still having problems such as waiting and losses in the processing process, the emergence of defects in crystal sugar products, and the occurrence of rework on the results of the production process that do not meet the standard specifications. To reduce these problems, a lean six sigma approach is used by the DMAIC method (Define, Measure, Analyze, Improve, Control), RCA (Root Cause Analysis), FMEA (Failure Mode and Effect Analysis), and alternative improvements based on the concept of kaizen (continuous incremental improvement) to eliminate processes that do not add value and reduce the occurrence of unfavorable variations in white crystal sugar production process. In this study, authors identify waste, the root cause and making suggestions to improve the quality of white crystal sugar products at PG Ngadiredjo Kediri, which is a sugar factory unit of PT Perkebunan Nusantara X. Waste identification is carried out based on the E-DOWNTIME classification such as on environmental, health and safety (EHS); defects; overproduction; waiting; unutilized talent; transportation; inventory; motion; excess processing. By implementing the proposed alternative improvements such as making form of routine inspections tools and cleaning instruments; conduct training and inspection of operator performance, established manual safety and supervision safety teams. It was found that there was an increase in the sigma level of each waste specifically from 2.51 to 2.94 for waiting waste; 2.78 to 3.26 for excess processing waste; 3.62 to 4.03 for EHS waste; 3.70 to 3.88 for inventory waste; 3.74 to 3.98 for transportation waste and 3.94 to 4.18 for defect waste. With this proposed improvement, it is hoped that it will facilitate PG Ngadiredjo to determining what corrective steps can be taken to reducing waste of white crystal sugar products in PG Ngadiredjo Kediri.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | E-DOWNTIME, Lean Six Sigma, Root Cause Analysis, FMEA, Perbaikan Kualitas, Lean Six Sigma, Root Cause Analysis, FMEA, Quality Improvement. |
| Subjects: | T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | Mr. Marsudiyana - |
| Date Deposited: | 19 Feb 2026 06:59 |
| Last Modified: | 19 Feb 2026 06:59 |
| URI: | http://repository.its.ac.id/id/eprint/132519 |
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