Analisis Dan Usulan Perbaikan Defect Pada Lini Produksi Packer Pt Japan Tobacco Indonesia Menggunakan Prinsip Six Sigma

Prabowo, Dhimas Brahmandhito (2026) Analisis Dan Usulan Perbaikan Defect Pada Lini Produksi Packer Pt Japan Tobacco Indonesia Menggunakan Prinsip Six Sigma. Diploma thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Tingginya tingkat defect pada lini produksi Packer di PT Japan Tobacco International Indonesia menjadi permasalahan kritis yang berdampak langsung terhadap efisiensi produksi dan kualitas produk akhir. Penelitian ini bertujuan untuk mengukur kinerja proses melalui nilai Defects Per Million Opportunities (DPMO) dan level sigma, menganalisis faktor-faktor penyebab utama terjadinya defect kritis, serta merumuskan usulan perbaikan yang aplikatif untuk mereduksi tingkat defect secara signifikan. Metode yang digunakan adalah Six Sigma dengan pendekatan DMAIC (Define, Measure, Analyze, Improve, Control) yang didukung oleh tools analisis berupa diagram SIPOC, diagram Pareto, Identifikasi Faktor Penyebab (4M1E), Five Why Analysis, dan Failure Mode and Effect Analysis (FMEA). Data bersumber dari sistem Manufacturing Data Collection (MDC) perusahaan yang mencakup 942 catatan kejadian dari 47 jenis defect dengan total 15.539 unit defect. Hasil penelitian menunjukkan bahwa kapabilitas proses lini Packer saat ini berada pada nilai DPMO sebesar 5.755,19 dengan level sigma sebesar 4,03. Dari 47 jenis defect yang teridentifikasi, delapan defect kritis menyumbang 80,95 persen dari total defect dan terbukti dipengaruhi oleh enam variabel X tematik yang terverifikasi melalui konfirmasi tiga filter yaitu kelemahan perawatan preventif, prosedur operasional, incoming quality control material, standar penyimpanan, pelatihan operator, dan koordinasi antar lini. Berdasarkan prioritas Risk Priority Number (RPN) dari hasil FMEA, dirumuskan enam rekomendasi perbaikan yang seluruhnya bersifat manajerial dan prosedural, didukung oleh Control Plan dan rekomendasi standarisasi SOP sebagai mekanisme pengendalian berkelanjutan.
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The high defect rate in the Packer production line at PT Japan Tobacco International Indonesia is a critical issue that directly impacts production efficiency and final product quality. This study aims to measure process performance through Defects Per Million Opportunities (DPMO) and sigma level, analyze the root causes of critical defects, and formulate applicable improvement proposals to significantly reduce the defect rate. The method employed is Six Sigma with the DMAIC (Define, Measure, Analyze, Improve, Control) approach, supported by analytical tools including SIPOC diagram, Pareto diagram, Analysis 4M1E, Five Why Analysis, and Failure Mode and Effect Analysis (FMEA). Data were obtained from the company's Manufacturing Data Collection (MDC) system comprising 942 defect occurrence records from 47 defect types with a total of 15,539 defected units. The results show that the current process capability of the Packer production line stands at a DPMO value of 5,755.19 with a sigma level of 4.03. Of the 47 identified defect types, eight critical defects accounting for 80.95 percent of total defects were proven to be influenced by six thematic X variables verified through a three-filter confirmation, namely weaknesses in preventive maintenance, operational procedures, incoming quality control of materials, material storage standards, operator technical training, and inter-line coordination. Based on the Risk Priority Number (RPN) priority from the FMEA results, six improvement recommendations were formulated, all of which are managerial and procedural in nature, supported by a Control Plan and SOP standardization recommendations as a sustainable control mechanism.

Item Type:	Thesis (Diploma)
Uncontrolled Keywords:	Six Sigma, DMAIC, Defect, DPMO, Lini Packer, Pengendalian Kualitas, FMEA, Diagram Pareto. Six Sigma, DMAIC, Defect, DPMO, Packer Line, Quality Control, FMEA.
Subjects:	Q Science > Q Science (General)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Dhimas Brahmandhito Prabowo
Date Deposited:	31 Jul 2026 07:21
Last Modified:	31 Jul 2026 07:21
URI:	http://repository.its.ac.id/id/eprint/140825

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