Analisis Kapabilitas Proses Produksi Rokok pada Multi-Quality Characteristics dengan Pendekatan Six Sigma Dmaic pada Lini Produksi Mp 07 di Pabrik Rokok

Haryanto, Belva Mahawira (2026) Analisis Kapabilitas Proses Produksi Rokok pada Multi-Quality Characteristics dengan Pendekatan Six Sigma Dmaic pada Lini Produksi Mp 07 di Pabrik Rokok. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Production Line MP 07 yang memproduksi Sigaret Kretek Mesin (SKM) pada kecepatan 4.350 rpm menghadapi keluhan konsumen terkait inkonsistensi tahanan hisap, variasi rasa, dan ketidakseragaman fisik produk, sementara data inline rejection periode Februari 2026 mencatat defect rate sebesar 1,414% (Defect Per Million Opportunities 14.139) dengan End Density dan Total Ventilation berkontribusi 88,03% dari total reject. Penelitian ini bertujuan menganalisis stabilitas dan kapabilitas proses pada enam quality characteristics (Gross Weight, Pressure Drop, Capsule Pressure Drop, Filter Ventilation, Circumference, Ovality) yang diturunkan dari empat Critical to Quality konsumen, serta merancang usulan perbaikan untuk meningkatkan Average Cpk menuju target ≥ 1,33. Metodologi Six Sigma DMAIC diterapkan melalui SIPOC dan identifikasi CTQ pada fase Define; X̄-S chart, uji Anderson-Darling, dan perhitungan Cp/Cpk pada fase Measure; fishbone diagram dengan kerangka 6M dan metode 5 Whys pada fase Analyze; Cpk Projection Analysis pada fase Improve; serta Control Plan dan rekomendasi pembaruan SOP pada fase Control. Hasil fase Measure menunjukkan tiga parameter berstatus incapable, yaitu Gross Weight (Cpk = 0,91), Ovality (Cpk = 0,93), dan Filter Ventilation (Cpk = 0,93), serta tiga parameter berstatus marginal, yaitu Capsule Pressure Drop (Cpk = 1,07), Pressure Drop (Cpk = 1,11), dan Circumference (Cpk = 1,19), dengan Average Cpk baseline 1,023, Minimum Cpk = 0,91, dan Rolled Throughput Yield ≈ 98,62% (≈ 13.839 PPM). Fase Analyze mengidentifikasi sembilan akar penyebab yang didominasi kategori Method (delapan dari sembilan), dengan frekuensi stop dan startup mesin sebagai pengungkit utama lintas parameter. Fase Improve merancang sembilan aksi spesifik dan implementasi Integrated Work System (IWS) berbasis benchmarking internal, dengan Cpk Projection Analysis tiga skenario memproyeksikan Average Cpk menjadi 1,14 (konservatif, r = 10%), 1,20 (moderat, r = 15%), dan 1,28 (optimistis, r = 20%) tanpa trade-off negatif antar parameter. Target Cpk ≥ 1,33 memerlukan pendekatan dua tahap: implementasi IWS diikuti eskalasi aksi spesifik per parameter. Keberlanjutan perbaikan dijamin melalui Control Plan dan delapan rekomendasi pembaruan SOP.
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Production Line MP 07, which manufactures Sigaret Kretek Mesin (SKM) at 4,350 rpm, continues to face consumer complaints regarding inconsistent draw resistance, taste variation, and non-uniform physical appearance, while February 2026 inline rejection data recorded a defect rate of 1.414% (Defect Per Million Opportunities 14,139), with End Density and Total Ventilation contributing 88.03% of total rejects. This study aims to analyze process stability and capability across six quality characteristics (Gross Weight, Pressure Drop, Capsule Pressure Drop, Filter Ventilation, Circumference, and Ovality) derived from four consumer Critical to Quality attributes, and to design improvement proposals to raise the Average Cpk toward a target of ≥ 1.33. The Six Sigma DMAIC methodology was applied through SIPOC and CTQ identification in the Define phase; X̄-S charts, Anderson-Darling normality testing, and Cp/Cpk calculation in the Measure phase; fishbone diagrams using the 6M framework and the 5 Whys method in the Analyze phase; Cpk Projection Analysis in the Improve phase; and a Control Plan with Standard Operating Procedure (SOP) update recommendations in the Control phase. The Measure phase revealed three incapable parameters, Gross Weight (Cpk = 0.91), Ovality (Cpk = 0.93), and Filter Ventilation (Cpk = 0.93) and three marginal parameters: Capsule Pressure Drop (Cpk = 1.07), Pressure Drop (Cpk = 1.11), and Circumference (Cpk = 1.19), with a baseline Average Cpk of 1.023, Minimum Cpk of 0.91, and Rolled Throughput Yield of approximately 98.62% (≈ 13,839 PPM). The Analyze phase identified nine verified root causes dominated by the Method category (eight of nine), with machine stop and startup frequency as the primary cross-parameter lever. The Improve phase designed nine parameter-specific actions and an Integrated Work System (IWS) implementation based on internal benchmarking; a three-scenario Cpk Projection Analysis projects the Average Cpk to 1.14 (conservative, r = 10%), 1.20 (moderate, r = 15%), and 1.28 (optimistic, r = 20%), with no negative trade-offs among parameters. Achieving the Cpk ≥ 1.33 target requires a two-stage roadmap: IWS implementation followed by escalation of parameter-specific actions. Sustainability of improvements is ensured through a Control Plan and eight SOP update recommendations.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Cpk, DMAIC, kapabilitas proses, multi-quality characteristics, pengendalian kualitas, Sigaret Kretek Mesin, Six Sigma, Cpk, DMAIC, Machine-Made Clove Cigarette, multi-quality characteristics, process capability, quality control, Six Sigma
Subjects:	Q Science Q Science > Q Science (General)
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Belva Mahawira Haryanto
Date Deposited:	28 Jul 2026 08:39
Last Modified:	28 Jul 2026 08:39
URI:	http://repository.its.ac.id/id/eprint/138916

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