Penerapan Metode DMAIC untuk Reduksi Cacat Produk Genteng (studi kasus : PT. Pabrik Ganteng ABC)

Ishaq, Hasan (2019) Penerapan Metode DMAIC untuk Reduksi Cacat Produk Genteng (studi kasus : PT. Pabrik Ganteng ABC). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. Pabrik Genteng ABC, salah satu perusahaan genteng terkemuka di Surabaya, dalam proses produksi aktualnya masih terdapat defect yang cukup tinggi. Berdasarkan data 2013-2017, jumlah cacat produk yang dihasilkan adalah sebesar 20-25% sehingga menjadi masalah perusahaan. Untuk mengatasi masalah ini, perlu dilakukan penelitian tentang faktor – faktor penyebab timbulnya cacat produk.
Dalam penelitian ini dilakukan evaluasi pada seluruh proses produksi untuk menemukan proses yang menghasilkan cacat yang besar. Kemudian, metode DMAIC (define, measure, analysis, improve, control) digunakan untuk menyelesaikan permasalahan. Pada tahap analisa digunakan metode RCA (root cause analysis) untuk mendapatkan akar permasalahan. Tahap berikutnya dilakukan usulan perbaikan untuk mengatasi permasalahan yang dapat menimbulkan cacat genteng. Terakhir, metoda pengendalian kualitas diterapkan agar permasalahan tidak timbul kembali.
Dari hasil penelitian didapatkan bahwa cacat terbesar ditimbulkan pada proses pengeringan hingga pembakaran genteng. Akar permasalahan yang menyebabkan cacat retak, cuil, dan pecah yaitu dengan karyawan dikejar target namun tidak adanya alat bantu untuk proses pembongkaran dari rak pengeringan, kondisi lantai area produksi yang belum pernah dilakukan renovasi, tidak adanya alat bantu dalam proses bongkar muat dilokasi pembakaran sehingga terjadinya proses bongkar muat sebanyak 2 kali. Untuk cacat melengkung disebabkan kondisi nampan kayu yang sudah berulang kali digunakan dan tidak ada proses penyortiran nampan sebelum digunakan. Kemudian cacat warna tidak rata disebabkan karyawan teledor saat bekerja pada shift malam. Selanjutnya dilakukan usulan perbaikan berupa pengadaan alat bantu untuk pekerjaan karyawan, perbaikan lantai produksi area kerja, pembuatan SOP pensortiran nampan, pemasangan alarm pengingat pada area kerja pembakaran.
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PT. ABC Tile Factory, one of the leading tile companies in Surabaya, in the actual production process there is still a high defect. Based on 2013-2017 data, the number of defects in the products produced is 20-25%, which is a problem for the company. To overcome this problem, it is necessary to do research on the factors that cause product defects.
In this study an evaluation of the entire production process was carried out to find a process that produced a large defect. Then, the DMAIC method (define, measure, analysis, improve, control) is used to solve the problem. In the analysis phase, the RCA (root cause analysis) method is used to get the root cause. The next stage is a proposed improvement to overcome problems that can cause tile defects. Finally, quality control methods are implemented so that problems do not arise again.
From the results of the study it was found that the biggest defects were caused by the drying process to the burning of tiles. The root of the problem that causes crack, chunk, and broken defects is that the employee is pursued by the target but there is no aid for the process of dismantling the drying rack, the condition of the floor of the production area that has never been renovated, the absence of loading and unloading loading and unloading process 2 times. For curved defects caused by the condition of wood trays that have been repeatedly used and there is no process of sorting trays before use. Then uneven color defects are caused by careless employees while working on the night shift. Subsequently proposed improvements in the form of procurement of tools for employee work, repair of work area production floor, making SOP sorting trays, installation of alarm reminders in the burning work area.

Item Type:	Thesis (Undergraduate)
Additional Information:	RSM 658.562 Ish p-1 2019
Uncontrolled Keywords:	defect, root cause analysis, DMAIC
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD9980.5 Service industries--Quality control. T Technology > TJ Mechanical engineering and machinery
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User:	Hasan Ishaq
Date Deposited:	27 Sep 2021 18:23
Last Modified:	27 Sep 2021 18:23
URI:	http://repository.its.ac.id/id/eprint/61251

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