Analisis Cost Of Quality Proses Bagging Pupuk Urea Menggunakan Model Prevention-Appraisal-Failure pada Perusahaan Industri Pupuk

Ramadhan, Shandy Rizki (2026) Analisis Cost Of Quality Proses Bagging Pupuk Urea Menggunakan Model Prevention-Appraisal-Failure pada Perusahaan Industri Pupuk. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses pengantongan pupuk urea merupakan tahap akhir produksi yang menentukan kualitas produk sebelum didistribusikan kepada konsumen. Area Bagging 2 PT XYZ beroperasi secara semi-otomatis pada 3 lini mesin dengan volume pengantongan sebesar 533.802 ton pada tahun 2025. Penelitian ini mengidentifikasi, mengklasifikasikan, dan menghitung seluruh komponen Cost of Quality menggunakan model Prevention-Appraisal-Failure serta menganalisis biaya kegagalan menggunakan Root Cause Analysis berdasarkan data internal perusahaan pada periode Januari 2023 hingga Desember 2025. Hasil identifikasi menunjukkan 19 elemen biaya kualitas, terdiri dari 9 elemen biaya CoGQ dan 10 elemen biaya CoPQ, yang mencakup aktivitas pencegahan, penilaian, kegagalan internal, dan kegagalan eksternal. Total COQ tercatat Rp 15.939.717.288 pada tahun 2023, Rp 14.913.658.697 pada tahun 2024, dan Rp 14.497.687.836 pada tahun 2025. CoPQ mendominasi struktur biaya kualitas dan menimbulkan kerugian finansial sebesar Rp 33.393.483.993 selama tiga tahun pengamatan, dengan biaya kegagalan eksternal sebagai komponen yang dominan sebesar 64,21% dari CoPQ dengan nominal Rp 21.441.807.560 akibat kesalahan penanganan karung pada proses distribusi ke atas kapal yang menyumbang 62,25% dari total biaya kegagalan. Temuan Root Cause Analysis menunjukkan bahwa dominasi biaya tersebut bersumber dari faktor human error dan metode kerja pada tahap loading kapal. Dengan ketiga tahun memiliki CoPQ di atas 70%, posisi biaya kualitas perusahaan berada di zone of improvement projects, yang mengindikasikan urgensi investasi pada aktivitas pencegahan untuk menekan kerugian jangka panjang. Rekomendasi perbaikan meliputi peningkatan pelatihan dan pengawasan prosedur kerja bagi tenaga kerja bongkar muat, implementasi fully automatic bagging & palletizer, dan pemasangan load cell pada conveyor untuk mendukung deteksi dini penyimpangan berat produk.
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The urea bagging process is the final stage determining product quality prior to distribution. PT XYZ's Bagging Area 2 operates a semi-automatic system across 3 machine lines, with a bagging volume of 533,802 tons in 2025. This study identifies, classifies, and calculates Cost of Quality components using the Prevention-Appraisal-Failure model and analyzes failure costs using Root Cause Analysis, based on internal data from January 2023 to December 2025. Results show 19 quality cost elements, comprising 9 Cost of Good Quality elements and 10 Cost of Poor Quality elements, covering prevention, appraisal, internal failure, and external failure activities. Total Cost of Quality was Rp 15.939.717.288 in 2023, Rp 14.913.658.697 in 2024, and Rp 14.497.687.836 in 2025. Cost of Poor Quality dominated the cost structure, generating a financial loss of Rp 33.393.483.993 over three years, with external failure cost as the dominant component, accounting for 64.21% of Cost of Poor Quality worth Rp 21.441.807.560, caused by handling errors during shipboard distribution, contributing 62.25% of total failure cost. Root Cause Analysis findings indicate that this cost dominance stems from human error and inadequate work methods during ship loading. With Cost of Poor Quality exceeding 70% in all three years, the company's quality cost position falls within the zone of improvement projects, indicating an urgent need for greater prevention investment to reduce long-term losses. Recommended improvements include enhanced training and procedure supervision for distribution personnel, implementation of fully automatic bagging and palletizing systems, and load cell installation on conveyors for early weight deviation detection.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Cost of Quality, model PAF, proses pengantongan, pupuk urea, Root Cause Analysis
Subjects:	T Technology > TS Manufactures > TS167 Costs, Industrial
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Shandy Rizki Ramadhan
Date Deposited:	30 Jul 2026 00:57
Last Modified:	30 Jul 2026 00:57
URI:	http://repository.its.ac.id/id/eprint/139911

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