Laporan Akhir Magang 1 Juli - 23 Desember 2025 di PT. DSM-Firmenich Indonesia

Thufailah, Gladys Sukma (2025) Laporan Akhir Magang 1 Juli - 23 Desember 2025 di PT. DSM-Firmenich Indonesia. Project Report. [s.n.]. (Unpublished)

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Abstract

Industri manufaktur flavor dituntut untuk meningkatkan efisiensi proses produksi melalui pengendalian penggunaan bahan baku tanpa mengurangi kualitas produk. Pada proses produksi Durarome di DSM-Firmenich Karawang, ditemukan adanya deviasi antara konsumsi aktual flavor oil dengan standar Bill of Material (BOM) sebesar 9,86% yang berpotensi menyebabkan peningkatan biaya produksi dan penurunan efisiensi proses. Penelitian ini bertujuan untuk mengidentifikasi faktor penyebab terjadinya pemborosan flavor oil serta merancang strategi perbaikan untuk menurunkan deviasi konsumsi bahan baku terhadap standar BOM. Metode yang digunakan dalam penelitian ini adalah pendekatan Lean Six Sigma dengan metode DMAIC (Define, Measure, Analyze, Improve, Control). Pengumpulan data dilakukan melalui observasi proses produksi Continuous Durarome Line 3 (CDL3), analisis data konsumsi aktual flavor oil, batch record, standar BOM, serta dokumen produksi perusahaan. Tahap analisis dilakukan menggunakan beberapa tools peningkatan proses seperti Pareto Chart, fishbone diagram, serta identifikasi Critical to Quality (CTQ) untuk menentukan faktor utama penyebab variasi proses. Hasil analisis menunjukkan bahwa faktor utama penyebab tingginya konsumsi flavor oil berasal dari ketidaksesuaian kompatibilitas bahan pembentuk Durarome, ketidakstabilan proses emulsifikasi, serta adanya potensi oil loss pada beberapa tahapan proses produksi. Berdasarkan implementasi solusi perbaikan melalui optimasi proses, diperoleh penurunan deviasi konsumsi flavor oil terhadap BOM dari 9,86% menjadi 0,721%, dengan potensi penghematan bahan baku sebesar 263,22 kg dan nilai penghematan tahunan mencapai Rp5,26 miliar. Berdasarkan hasil penelitian, penerapan metode DMAIC mampu meningkatkan efisiensi penggunaan bahan baku, mengurangi variasi proses, serta menjaga konsumsi flavor oil agar lebih sesuai dengan standar BOM. Implementasi sistem kontrol dan standardisasi proses diperlukan untuk mempertahankan hasil perbaikan secara berkelanjutan.
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The flavor manufacturing industry is required to continuously improve production efficiency by controlling raw material usage while maintaining product quality. In the Durarome production process at DSM-Firmenich Karawang, a deviation was identified between actual flavor oil consumption and the Bill of Material (BOM) standard, reaching 9.86%. This deviation potentially increases production costs and reduces process efficiency. This study aims to identify the root causes of excessive flavor oil consumption and develop improvement strategies to reduce raw material usage deviation from the BOM standard. This study applied a Lean Six Sigma approach using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. Data collection was conducted through direct observation of the Continuous Durarome Line 3 (CDL3) production process, analysis of actual flavor oil consumption data, batch records, BOM standards, and production documents. The analysis phase was performed using process improvement tools, including Pareto Chart, fishbone diagram, and Critical to Quality (CTQ) identification to determine the main factors contributing to process variation. The results indicated that the main causes of excessive flavor oil consumption were incompatibility between Durarome-forming materials, instability during the emulsification process, and oil losses occurring at several production stages. After implementing improvement strategies through process optimization, the deviation between actual flavor oil consumption and BOM was reduced from 9.86% to 0.721%. The improvement resulted in a potential raw material saving of 263.22 kg and an estimated annual cost saving of approximately IDR 5.26 billion. In conclusion, the implementation of the DMAIC methodology successfully improved raw material efficiency, reduced process variation, and enhanced consistency between actual flavor oil consumption and BOM standards. Continuous monitoring and process standardization are required to sustain the achieved improvements.

Item Type:	Monograph (Project Report)
Uncontrolled Keywords:	DMAIC, Lean Six Sigma, Flavor Oil, Bill of Material, Durarome, Efisiensi Produksi
Subjects:	Q Science > QD Chemistry > QD251.2 Chemistry, Organic. Biochemistry
Divisions:	Faculty of Vocational > 24305-Industrial Chemical Engineering Technology
Depositing User:	Gladys Sukma Thufailah
Date Deposited:	17 Jul 2026 08:57
Last Modified:	17 Jul 2026 08:57
URI:	http://repository.its.ac.id/id/eprint/135305

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