Rahayu, Arum Rediawati (2016) Implementasi Metode Lean Six Sigma Untuk Mereduksi Waste Pada Produk Pasted Kraft Di Pt Industri Kemasan Semen Gresik. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Perusahaan akan berlomba-lomba dalam meningkatkan kualitas produk
demi memenuhi kepuasan pelanggan. Selain itu, perusahaan juga akan menekan
biaya produksi seminimal mungkin untuk mendapatkan keuntungan semaksimal
mungkin. Demikian pula pada PT Industri Kemasan Semen Gresik (IKSG).
Perusahaan ini memproduksi kantong sebagai pembungkus semen dan merupakan
anak perusahaan dari PT Semen Gresik. Permasalahan di perusahaan ini adalah
banyaknya pemborosan (waste) di lantai produksi dan adanya komplain pelanggan
terkait kualitas produk. Permasalahan tersebut menimbulkan dampak berupa
kerugian finansial bagi perusahaan dan penurunan reputasi perusahaan di mata
konsumen. Kerugian finansial yang ditimbulkan akibat adanya permasalahan
tersebut mencapai lebih dari 2 Milyar Rupiah untuk masing-masing line produksi.
Oleh karena itu, dibutuhkan suatu langkah perbaikan untuk menyelesaikan
permasalahan tersebut. Lean six sigma diusulkan untuk diimplementasikan dalam
upaya mengatasi permasalahan yang ada. Waste yang teridentifikasi di PT IKSG
adalah waiting, defect dan environmental, health and safety. Ketiga waste tersebut
kemudian dihitung performansinya berdasarkan nilai sigma. Nilai sigma dari
masing-masing waste rata – rata masih berada dalam rentang 2 sampai 4 sehingga
perlu adanya perbaikan untuk meningkatkan performansinya. Langkah selanjutnya
adalah mencari akar penyebab permasalahan menggunakan 5 whys pada root cause
analysis. Setelah itu, akan diprioritaskan risiko terjadinya waste tersebut
berdasarkan severity, occurence dan detection pada failure mode and effects
analysis. Dalam penelitian ini diusulkan 3 alternatif perbaikan dan kombinasinya
untuk kemudian dipilih yang terbaik menggunakan pendekatan value berdasarkan
pada performansi dan biayanya. Hasil perbaikan terbaik adalah pengadaan form
pengontrolan kondisi mesin setiap harinya dan adanya pengawas lapangan untuk
mengawal adanya sistem reward and punishment. Dengan adanya improvement
tersebut, defect dapat direduksi sebanyak 25%, downtime dapat direduksi sebanyak
17% dan peningkatan kualitas kesehatan dan keselamatan kerja sebesar 38%. Dapat
disimpulkan bahwa perbaikan yang diusulkan memberikan dampak yang baik bagi
perusahaan.
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Companies would compete in improving the quality of products to meet
customer satisfaction. They also reduce production cost as least as possible to get
maximum profit. One of them is PT Industri Kemasan Semen Gresik (IKSG). This
company produces kraft as a cement packer and included one of the members of PT
Semen Gresik. But, PT IKSG has many problems where there are many waste in
production floor and complaint related customer quality products. That problems
make bad impact for the company namely financial losses and reputation reduction
by the customer. Financial losses as a consequence of that problems are more than
2 billion rupiahs for each production line. Hence, an improvement to solves those
problems is required. Lean six sigma is proposed to solve those problems. The
waste that identified are waiting, defect and environmental, health and safety. After
identifying the waste, it would be counted the company performance based on
sigma value for each waste. Sigma value for each waste is average on 2 until 4, so
it needs an improvement to increase the company performance. Based on its
performance, it would be identified the root cause by using 5 whys in Root Cause
Analysis. Potential cause that identified would be prioritized based on its severity
occurrence, and detection by using Failure Mode and Effects Analysis. In this final
project, there are 3 alternative improvements and its combination are proposed and
they would be selected the best way based on value of their performance and costs.
The best improvements are creating daily machine conditional control form and
hiring supervisor to escort the reward and punishment system. With these
improvements, there are reduction of defect by 25% and downtime by 17% and
improvement of quality health and occupational healthy by 38%. This
improvements give good impact to the company.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.562 Rah i |
| Uncontrolled Keywords: | Lean Six Sigma, Waste, Root Cause Analysis, Failure Mode And Effects Analysis, Pendekatan Value. |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | EKO BUDI RAHARJO |
| Date Deposited: | 04 Nov 2019 08:11 |
| Last Modified: | 04 Nov 2019 08:11 |
| URI: | http://repository.its.ac.id/id/eprint/71586 |
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