Asma, Muhammad Ramadhan (2016) Penerapan Lean Six Sigma Untuk Mereduksi Waste Dan Peningkatan Kualitas Pada Proses Produksi Bogie S2hd-9c. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT. Barata Indonesia merupakan salah satu BUMN yang bergerak di bidang
metal works dan engineering. Salah satu pelanggan dari PT.Barata yang telah
melakukan kerjasama bisnis adalah pihak Standard Car Truck (SCT) untuk
memesan produk bogie jenis S2HD-9C. Permasalahan yang dihadapi oleh
perusahaan terkait proses produksi bogie S2HD-9C adalah rendahnya kualitas
produk (defect), rendahnya kapasitas mesin (waiting) serta banyaknya frekuensi
rework yang dilakukan terhadap produk cacat (excess processing). Untuk
menghadapi permasalahan tersebut PT. Barata Indonesia perlu meningkatkan
kinerja produktivitas produksi untuk dapat meningkatkan kualitas dan ketepatan
waktu pengiriman produk kepada pelanggan. Penulis mencoba menemukan solusi
dari permasalahan ini dengan menggunakan konsep Lean Six Sigma untuk
memperbaiki kualitas produk bogie S2HD-9C. Tools yang digunakan dalam
penelitian ini adalah Value Stream Mapping (VSM) yang digunakan untuk
memperoleh gambaran secara jelas tentang aliran fisik dan aliran informasi unit
produksi bogie , sedangkan untuk mencari akar penyebab permasalahan diterapkan
metode Root Cause Analysis. Untuk memperoleh nilai Risk Priority Number (RPN)
serta mendapatkan alternatif solusi dilakukan metode FMEA dan untuk pemilihan
alternatif solusi terbaik digunakan konsep Value management.
Sehingga dari hasil penelitian didapatkan bahwa jenis defect yang sering
terjadi selama proses produksi bogie adalah shrinkage, crack, dan sand drop.
Dampak lain yang ditimbulkan dari adanya defect adalah perlunya dilakukan proses
rework terhadap produk cacat sehingga terjadinya peningkatan lead time produksi.
Untuk waiting waste paling kritis terjadi akibat adanya downtime mesin induction
furnace dan arc furnace akibat padatnya kapasitas penggunaan mesin. Berdasarkan
identifikasi terhadap waste kritis, dipilih usulan alternatif perbaikan yaitu
pembentukan tim total productive maintenance dan penelitian peningkatan kualitas
pengecoran komponen bolster dan side frame. Dimana penerapan alternatif tersebut
berpengaruh terhadap kenaikan nilai sigma sebesar 0,29% untuk defect waste,
pengurangan waktu downtime mesin produksi sebesar 19,12% dan kenaikan nilai
sigma sebesar 0,29% untuk excess processing waste.
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PT. Barata Indonesia is a BUMN that focused in metal works and
engineering segment. One of the client that have done business cooperation for
PT.Barata Indonesia’s product is SCT to order products bogie types S2HD-9C.
Currently, the company focused in improvement to reduce the problems in the
production process. This effort is conducted in order the company was able to fulfill
customer satisfaction about product quality. The problem that company faced is
about the low quality of product (defect), the low capacity of the machine (waiting)
and the higher number of frequency rework done on defective products (excess
processing). To solve these problems, the company need lean six sigma methods
which focused to reduce waste and non-value added activity such like defect and
waiting. This method is also used to minimize the resources that must be issued by
the company for improvements, because by using this method, the problem will be
more clear so there is no decision-making errors. This study measures
based of framework six sigma define, measure, analyze, improvement and control
(DMAIC). To identify a problem, we used value stream mapping (VSM), E-waste
DOWNTIME and activity classification. As for the search of critical issues used
pareto charts, financial analysis, RCA, FMEA and find the best alternative by using
value engineering .
As the result of this research, there are founded three critical waste in the
production process of bogie S2HD-9C, that three wastes are defect, waiting, and
excess processing as well as the root cause of the problem is most critical. Based
on these results, three arranged alternatives will be selected by the method of value
management. From 3 alternative solutions prepared, we selected 2 alternatives,
which are establishment of a team of total productive maintenance, and research to
improve the quality of casting components bolster and side frame. Where all of the
alternatives are expected to have an impact on the reduced number of defects,
waiting time and shorten the lead time.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSI 658.562 Asm p 3100016066671 |
| Uncontrolled Keywords: | Failure Mode and Effect Analysis (FMEA), Lean Six Sigma, Root use Analysis (RCA), Value Engineering, Waste |
| Subjects: | T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | - Davi Wah |
| Date Deposited: | 18 Mar 2020 02:25 |
| Last Modified: | 18 Mar 2020 02:25 |
| URI: | http://repository.its.ac.id/id/eprint/75428 |
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