Pengurangan Daur Ulang Limbah Zat Pewarna Dengan Moetode Six Sigma Di PT. DYSTAR Colours Indonesia

Rahayu, Widodo (2010) Pengurangan Daur Ulang Limbah Zat Pewarna Dengan Moetode Six Sigma Di PT. DYSTAR Colours Indonesia. S2 thesis, Universitas Mercu Buana Jakarta-Menteng.

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Abstract

Dye manufacture produced high amount of dye wastewater from cleaning equipments and house keeping after each batch operation. The wastewater characteristic can be highly variable from day to day depending on the type and colour of dye. In general, dye wastewater contains toxic organic residue out from synthesis or chemistry process, that why dye wastewater disposal has to be controlled precisely in order to ensure that disposal waste will not create environmental problem. Finishing department PT. DyStar Colours Indonesia Gabus Plant (DCI – GP) is producing semi-finished product to become finished product with physical treatment, which is basically no chemical reaction, this means dye wastewater generation out from Finishing plant is containing dyestuff and dispersing agent, thus the dye wastewater generated by Finishing process is possible to be re-used or re- cycled. In the first semester 2009, Finishing department DCI – GP generated in average 145 m3 dyes wastewater / day, thus the wastewater treatment cost is USD 3,159 / day from evaporation process, spray drying, and disposal the solid waste to landfill. Six Sigma is one of excellent and comprehensive system for achieving, sustaining and maximizing business success. Six Sigma is uniquely driven by close understanding of customer needs, disciplined use of facts, data and statistical analysis, and diligent attention to managing, improving and retaining business processes. Six Sigma with DMAIC system confirmed that by Defining and Measuring process the dyes wastewater generation can be reduced from 145 m3 / day to become 70.3 m3 / day after 3 months. By Analysis and Improvement process, dye wastewater generation can be reduced up to 20 m3 / day, and furthermore can be recycled or re- used to become finished product which can be sold locally with reasonable price. Total investment to implement this research / project is approx. USD 29,500 for purchasing and installing 40 units flow meter, 6 units water gun, 2 units floor scrubber, etc. with potential cost reduction Mio USD 1.15 per annum from reducing and recycling dyes wastewater generation in Finishing Plant. Sigma value in the first quarter 2010 after DMAIC system was successfully implemented is 3.2 sigma, and there is still room for improvement. Efforts which can be used to maintain and improve sigma value such as : create cleaning targets for every single equipment cleaning, install automatic cleaning system / CIP (Cleaning In Place) for production machines, streamlining dye wastewater generation based on color pattern in order to simplify recycle process of dye by-product.Industri zat pewarna tekstil menghasilkan limbah cair yang sangat banyak dari proses pencucian peralatan produksi dan kebersihan lingkungan kerja setiap pergantian batch. Limbah cair yang dihasilkan sangat bervariasi tergantung dari jenis dan corak zat pewarna yang diproduksi. Secara umum, limbah zat pewarna cair mengandung bahan berbahaya yang berasal dari proses reaksi kimia. Oleh karenanya proses pengolahan limbah cair harus dikontrol secara seksama agar tidak menimbulkan pencemaran lingkungan. Departemen Finishing PT. DyStar Colours Indonesia Gabus Plant (DCI – GP) memproduksi produk setengah jadi menjadi produk akhir melalui proses penggerusan particle dan standarisasi, sehingga tidak terjadi proses reaksi kimia yang menghasilkan zat berbahaya. Oleh karenanya, limbah zat pewarna cair yang dihasilkan departemen Finishing mengandung zat pewarna dan Dispersing Agent sebagai pelembut, sehingga dapat digunakan kembali (daur ulang / re-cycle). Selama semester pertama tahun 2009, departemen Finishing DCI – GP menghasilkan limbah zat pewarna cair rata-rata sebesar 145 m3/hari dengan biaya pengolahan limbah sebesar USD 3,159/hari yang berasal dari proses evaporasi, pengeringan limbah cair menjadi padatan, dan biaya pembuangan limbah padat ke landfill. Six Sigma adalah salah satu system yang kompehensif untuk memperoleh, mendukung dan memaksimalkan proses bisnis. Six Sigma secara unik dijalankan dengan cara pengertian mendalam kepada kebutuhan pelanggan, disiplin menggunakan fakta, data dan analisa, serta perhatian penuh untuk mengatur, meningkatkan, dan memelihara proses bisnis. Six Sigma dengan DMAIC sistem terbukti telah berhasil melalui proses Define dan Measure limbah zat pewarna cair yang dihasilkan dapat dikurangi dari 145 m3 /hari menjadi 70.3 m3 /hari setelah 3 bulan diukur. Melalui proses Analysis dan Improvement dapat ditekan lagi menjadi 20 m3 /hari, untuk selanjutnya dapat didaur ulang menjadi produk akhir yang dapat dijual kepada konsumen lokal dengan harga wajar. Total investment dari penelitian / proyek ini adalah sebesar USD 29,500 untuk pembelian dan pemasangan 40 unit flow meter, 6 unit water gun, 2 unit floor scrubber, dll. dengan potential penurunan biaya dari pengolahan limbah zat pewarna cair dan daur ulang by-product di departemen Finishing mencapai 1.15 juta USD selama setahun. Nilai sigma pada kuartal pertama tahun 2010 setelah DMAIC sistem sukses dijalankan adalah 3.2 sigma, sehingga masih ada ruang untuk ditingkatkan. Upaya- upaya lain yang dapat dilakukan untuk meningkatkan nilai sigma adalah : membuat target jumlah air yang digunakan untuk sekali proses pencucian, memasang alat pencucian otomatis / CIP (Cleaning In Place) untuk mesin produksi, mengelompokkan limbah zat pewarna cair sesuai arah warna untuk mempermudah proses daur ulang by- product.

Item Type: Thesis (S2)
Call Number CD: CDT-551-10-106
Call Number: TM/10/305
NIM/NIDN Creators: 55106020020
Uncontrolled Keywords: Daur Ulang Limbah, MPO, Manajemen oprasional
Subjects: 600 Technology/Teknologi > 650 Management, Public Relations, Business and Auxiliary Service/Manajemen, Hubungan Masyarakat, Bisnis dan Ilmu yang Berkaitan > 658 General Management/Manajemen Umum
Divisions: Pascasarjana > Magister Manajemen
Depositing User: Admin Perpus UMB
Date Deposited: 10 Mar 2011 11:53
Last Modified: 13 Feb 2023 03:23
URI: http://repository.mercubuana.ac.id/id/eprint/38245

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