Peningkatan Kualitas Komponen Transmisi Otomatis Dengan Pendekatan Metode Six Sigma

Malik, Rizki Abdul (2025) Peningkatan Kualitas Komponen Transmisi Otomatis Dengan Pendekatan Metode Six Sigma. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Penelitian ini dilakukan dengan mengintegrasikan pendekatan Six Sigma secara komprehensif dalam meningkatkan kualitas komponen steel bands pada proses produksi transmisi otomatis di Perusahaan Transmisi Otomatis (PTO). Pendekatan Six Sigma digunakan tidak hanya untuk mengidentifikasi akar masalah kualitas, tetapi juga untuk menerapkan strategi perbaikan yang terstruktur guna menurunkan tingkat defect secara signifikan hingga memenuhi standar industri. Permasalahan utama yang diangkat adalah tingginya persentase defect pada komponen steel bands, yang secara konsisten melebihi target capaian defect rete yaitu kurang dari 0,3% sebagaimana ditetapkan dalam Production Division Policy. Kondisi ini memberikan dampak negatif pada efisiensi produksi dan daya saing perusahaan, sehingga dibutuhkan sebuah metode analitis untuk merancang solusi perbaikan yang efektif dan berkelanjutan. Untuk menjawab permasalahan tersebut, penelitian ini menggunakan kerangka kerja Six Sigma dengan metode DMAIC (Define, Measure, Analyze, Improve, Control). Data dikumpulkan melalui studi lapangan di PTO dan tinjauan literatur terkait. Tahapan Define dilakukan dengan membuat flowchart proses produksi dan identifikasi kualitas dengan Critical to Quality (CTQ). Tahap Measure mencakup identifikasi fokus penelitian dengan penggunaan diagram Pareto, dan penghitungan sigma level awal. Pada tahap Analyze, akar masalah ditelusuri menggunakan diagram fishbone dan metode Five Whys. Tahapan Improve dilakukan dengan merancang dan mengimplementasikan solusi dari akar penyebab yaitu kurangnya kontrol terhadap jig yang digunakan. Terakhir, tahap Control digunakan untuk memonitor dan mengevaluasi hasil perbaikan serta mengukur ulang sigma level pasca implementasi. Hasil penelitian menunjukkan bahwa melalui pendekatan Six Sigma, identifikasi akar masalah dapat dilakukan secara sistematis, dan perbaikan yang diterapkan mampu menurunkan tingkat defect hingga mendekati target di bawah 0,3%. Selain itu, sigma level produksi meningkat, yang menunjukkan peningkatan kualitas proses secara keseluruhan.
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This study introduces a novel application of the Six Sigma approach to systematically improve the quality of steel bands components in the production process of automatic transmissions within an Indonesian manufacturing company, referred to as the Automatic Transmission Company (PTO). The innovation lies in the comprehensive use of Six Sigma not only to identify the root causes of quality issues but also to implement structured corrective actions aimed at significantly reducing defect rates to meet industrial standards. The core problem addressed in this research is the persistently high defect rate in steel bands components, which has consistently exceeded the acceptable limit of 0.3% as specified in the company's Production Division Policy Manual. Given the importance of the steel bands in ensuring product durability and customer satisfaction, a structured problem-solving method using the DMAIC (Define, Measure, Analyze, Improve, Control) cycle was adopted. During the Define phase, critical quality attributes (CTQ) were identified based on process mapping and discussions with production experts, highlighting key process points such as grinding, length adjustment, and surface hardening. The Measure phase involved data collection from production records to calculate DPMO (Defects Per Million Opportunities) and sigma levels. Pareto analysis revealed that scratch defects were the most dominant issue, especially occurring during length adjustment stages.In the Analyze phase, fishbone diagrams and five whys analysis identified the root causes of scratch defects. Factors such as inadequate handling, worn-out machine parts, and suboptimal material properties were highlighted. The Improve phase proposed solutions including updated handling procedures, maintenance schedules, and verification of material properties, which were implemented without increasing manpower or process cycle time. Verification included safety checks to ensure changes did not introduce new risks.Finally, the Control phase focused on evaluating improvements through revised control charts and monitoring systems. After improvement, the defect rate dropped significantly, and the sigma level increased to 5.03, reflecting better process capability and quality performance. This research demonstrates how Six Sigma tools and DMAIC methodology can effectively identify, analyze, and reduce defects in manufacturing, offering a model for continuous quality improvement.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Transmisi otomatis, DMAIC, kualitas, Six Sigma, manufaktur, Automatic transmission, DMAIC, Quality, Six Sigma, manufacturing
Subjects:	T Technology > TS Manufactures T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Rizki Abdul Malik
Date Deposited:	05 Aug 2025 03:19
Last Modified:	05 Aug 2025 03:19
URI:	http://repository.its.ac.id/id/eprint/127291

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