PENGURANGAN DEFECT PADA DEPARTEMEN JAHIT DENGAN MENGINTEGRASIKAN OTSM-TRIZ DAN FMEA

Hakim, M. Hanifuddin (2019) PENGURANGAN DEFECT PADA DEPARTEMEN JAHIT DENGAN MENGINTEGRASIKAN OTSM-TRIZ DAN FMEA. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Permasalahan yang terjadi pada PT Sepatu adalah masih banyak ditemukan produk defect. Untuk meningkatkan kualitas serta mengurangi jumlah defect yaitu dengan melakukan perbaikan pada aliran proses dengan mengunakan tahapan Define-Measure-Analyze-Improve. Pada tahap Define berisi penentuan defect kritis yang terpilih yaitu patahan jarum, jahitan loncat, jahitan kendor, Upper tidak simetri, dan Upper berkerut. Defect tersebut disebabkan beberapa hal antara lain; skill karyawan tisak sesuai standar, change over yang tinggi, jarum bengkok dari supplier, dsb. Adanya defect akan mengakibatkan tingkat kepuasan customer dan pendapatan menurun. Pada tahap Measure dilakukan pengukuran besar DPMO yaitu 4028 unit dan level sigma senilai 4,1.
Pada tahap Analize, melakukan analisa permasalahan kompleks yang menyebabkan defect di departemen jahit menggunakan Network of Problem (NoP). NoP digunakan untuk menguraikan permasalahan kompleks yang menimbulkan beberapa kontadiksi sekaligus sehingga TRIZ klasik tidak mampu untuk mengatasi permasalahan ini. Output dari Nop berupa partial solution (ps) dan sub problem (pb). Kedua output ini akan menjadi input FMEA, yang kemudian akan dilakukan analisa dan pengukuran nilai RPN. Intergrasi antara OTSM-TRIZ dengan FMEA digunakan untuk menentukan sub problem mana yang harus diselesaikan. Potential Failure Mode (s) dengan skor RPN tertinggi di tabel FMEA akan menjadi prioritas dan menjadi input awal prosedur tahapan OTSM-TRIZ. Dari perhitungan FMEA, terpilih defect jahitan loncat disebabkan rotari aus, defect jahitan kendor disebabkan setting tension benang berubah-rubah, defect patahan jarum disebabkan jarum bengkok, defect Upper tidak simetri dan Upper berkerut disebabkan skill karyawan tidak memenuhi standar serta defect jahitan loncat disebabkan jarum tumpul. Pada tahap Improve digunakan bantuan metode OTSM-TRIZ untuk mengakomodir kontradiksi yang terjadi dengan contradiction matrix dan 40 inventive principle. Prinsip pemecahan masalah yang terpilih akan menjadi pedoman pembuatan rekomendasi peningkatan kualitas. Dari hasil penerapan rekomendasi perbaikan estimasi pengurangan defect sebesar 705 pasang sepatu dengan level sigma 4,3 ============================================================The problems that occur in PT Sepatu are still many defect products. Defects are caused by several things, including; employee skills are not up to standard, high change over, bent needles from suppliers, etc. The existence of a defect will result in a low customer satisfaction level and decreased income. To improve quality and reduce the number of defects by making improvements to the process flow using the Define-Measure-Analyze-Improve step. In the Define stage, the determination of the selected critical defect is needle fracture, jump stitch, loose stitch, Upper symmetry, and Upper wrinkling. In the Measure phase, DPMO measurements were carried out at 4028 units and a sigma level of 4.1.
In the Analize stage, analyze complex problems that cause defects in the sewing department using Network of Problem (NoP). NoP is used to describe complex problems that give rise to several contradictions at the same time so that classic TRIZ is unable to overcome this problem. The output of Nop is in the form of partial solution (ps) and sub problem (pb). Both of these outputs will be FMEA inputs, which will then be analyzed and measured for the value of RPN. The integration between OTSM-TRIZ and FMEA is used to determine which sub-problems need to be resolved. The potential Failure Mode (s) with the highest RPN score in the FMEA table will be a priority and become the initial input to the OTSM-TRIZ stage procedure. From the FMEA calculation, selected jump stitch defects were caused by worn rotors, loose stitch defects caused by changing thread tension settings, needle fracture defects caused by bent needles, Upper symmetrical defect and Upper wrinkles caused by employee skills not meeting standards and jump stitch defects caused by blunt needles . In the Improve stage, the OTSM-TRIZ method is used to accommodate the contradictions that occur with the contradiction matrix and 40 inventive principles. The chosen problem solving principle will be a guideline for making quality improvement recommendations. From the results of the implementation of recommendations, improvements to the estimated defect reduction of 705 pairs of shoes with sigma 4.3 level.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	FMEA, Quality, NoP, OTSM-TRIZ, Six Sigma
Subjects:	T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	M. Hanifuddin Hakim
Date Deposited:	22 Jul 2026 07:48
Last Modified:	22 Jul 2026 07:48
URI:	http://repository.its.ac.id/id/eprint/67100

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