Perancangan Pengendalian Kerusakan Kemasan Berbasis Root Cause Analysis dan FMEA (Studi Kasus pada PT Central Proteina Prima)

Pratama, Fauzan Kemal (2026) Perancangan Pengendalian Kerusakan Kemasan Berbasis Root Cause Analysis dan FMEA (Studi Kasus pada PT Central Proteina Prima). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Kemasan merupakan bahan pendukung yang penting untuk menjaga kelancaran proses produksi dan distribusi. Kerusakan kemasan dapat mengurangi jumlah kemasan yang masih layak digunakan, menambah pekerjaan penanganan ulang, serta menyebabkan perbedaan antara catatan persediaan dan kondisi fisik di gudang. Selama periode November 2025 hingga April 2026, tercatat 2.285 kasus kerusakan kemasan atau rata-rata 381 kasus per bulan. Sementara itu, rata-rata Fill Rate sebesar 90,9% digunakan sebagai indikator pendukung untuk menggambarkan kemampuan gudang dalam memenuhi kebutuhan kemasan. Penelitian ini bertujuan menentukan jenis kemasan dan bentuk kerusakan yang menjadi prioritas, mencari penyebab utama kerusakan, menentukan urutan risiko, serta menyusun rancangan pengendalian. Penelitian menggunakan pendekatan mixed methods dengan desain studi kasus deskriptif terapan. Analisis Pareto digunakan untuk menentukan jenis kemasan yang paling banyak mengalami kerusakan. Root Cause Analysis digunakan untuk menelusuri penyebab utama kerusakan. Failure Mode and Effects Analysis digunakan untuk menentukan urutan risiko, sedangkan metode 5W+1H digunakan untuk menyusun tindakan pengendalian secara terarah. Hasil Analisis Pareto menunjukkan bahwa B1, A4, dan B2 merupakan tiga jenis kemasan dengan jumlah kerusakan tertinggi, masing-masing sebanyak 208, 195, dan 178 kasus. Bentuk kerusakan yang paling sering terjadi adalah penyok dengan jumlah 215 kasus. Hasil RCA menunjukkan bahwa kerusakan terutama disebabkan oleh prosedur kerja yang belum cukup jelas, pelatihan dan pengawasan yang belum berjalan secara terpadu, serta sistem pemisahan dan pencatatan kemasan rusak yang belum tertata dengan baik. Hasil FMEA menghasilkan nilai RPN sebesar 343, 336, 336, dan 288 pada risiko yang dianalisis. Usulan pengendalian yang disusun meliputi SOP, checklist pemeriksaan, form pencatatan kerusakan, area karantina, visual control, pelatihan, inspeksi, pembatasan tumpukan, dan pembaruan data stok. Hasil analisis telah sesuai secara perhitungan, tetapi sebagian temuan masih memerlukan validasi resmi dari perusahaan. Target penurunan kerusakan sebesar 50% dan pencapaian Fill Rate sebesar 95% merupakan target setelah penerapan, bukan hasil aktual penelitian.
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Packaging is an important supporting material that helps production and distribution activities run smoothly. Damaged packaging can reduce the amount of packaging that is still suitable for use, create additional handling work, and cause differences between inventory records and the actual stock in the warehouse. From November 2025 to April 2026, 2,285 cases of packaging damage were recorded, with an average of 381 cases per month. During the same period, the average Fill Rate was 90.9% and was used only as a supporting indicator of the warehouse’s ability to meet packaging needs. This study aims to identify the packaging types and forms of damage that should be prioritized, determine the main causes of damage, rank the risks, and develop a packaging damage control plan. The study used a mixed-methods approach with an applied descriptive case study design. Pareto analysis was used to identify the packaging types with the highest number of damage cases. Root Cause Analysis was used to find the main causes of damage. Failure Mode and Effects Analysis was used to rank the risks, while 5W+1H was used to prepare structured control actions. The results showed that B1, A4, and B2 had the highest numbers of damage cases, with 208, 195, and 178 cases, respectively. Dents were the most common form of damage, with a total of 215 cases. The Root Cause Analysis showed that the main problems were unclear procedures, uncoordinated training and supervision, and an inadequate system for separating and recording damaged packaging. The Failure Mode and Effects Analysis produced Risk Priority Number values of 343, 336, 336, and 288. The proposed control measures include standard operating procedures, inspection checklists, packaging damage recording forms, a quarantine area, visual control, operator training, inspections, stacking limits, inventory updates, and a 5W+1H-based Action Plan. The calculations were consistent, but several findings still require formal approval and validation from the company. A 50% reduction in packaging damage and a 95% Fill Rate are implementation targets and should not be considered actual results of this study.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	FMEA, Inventory Control, Packaging Damage, Root Cause Analysis, Warehouse. FMEA, Gudang, Kerusakan Kemasan, Pengendalian Persediaan, Root Cause Analysis.
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management H Social Sciences > HD Industries. Land use. Labor > HD62.15 Total quality management.
Divisions:	Faculty of Creative Design and Digital Business (CREABIZ) > Business Management > 61205-(S1) Undergraduate Thesis
Depositing User:	Fauzan Kemal Pratama
Date Deposited:	31 Jul 2026 01:39
Last Modified:	31 Jul 2026 01:39
URI:	http://repository.its.ac.id/id/eprint/137069

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