SAMUDRA, JHODY RIOBY (2026) ANALISIS PENGENDALIAN KUALITAS PROSES SABLON PADA PRODUK KAOS CUSTOM MENGGUNAKAN METODE DMAIC DI UMKM 268ID CLOTHING. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
268ID Clothing is a custom t-shirt convection and printing micro-enterprise using the Direct transfer film (DTF) method that still faces a high product defect rate. Based on production data for January–September 2025, the defect rate reached 8.94%, exceeding the company's tolerance limit of 3%, indicating that the process was not under control. This study aims to identify the dominant defect types, analyze their main contributing factors, and formulate improvement proposals. The method used is Six sigma with the DMAIC approach (Define, Measure, Analyze, Improve, Control). The define stage identifies defects through a check sheet, CTQ, and a SIPOC diagram; the measure stage assesses process capability through DPMO, the sigma level, and a P control chart; the analyze stage determines priorities using a Pareto diagram and root causes through a cause-and-effect diagram and Failure Mode and Effect Analysis (FMEA); the improve stage formulates proposals using the 5W+1H method; and the control stage develops a Control Plan. The results show two dominant defects, namely imprecise print position (42.19%) and peeling print (29.96%), with a cumulative contribution of 72.15%. The process is at a sigma level of 3.22 with an average DPMO of 433.59, indicating low process capability, while all points on the P control chart lie within the control limits, showing that the defects are common-cause in nature. The proposed improvements include using a DTF ruler, preparing SOPs for placement and press parameters, adding a reference grid, machine calibration, and operator training, consolidated into an SOP and maintained through a Control Plan to reduce defects sustainably. Keywords: Quality, Six sigma, DMAIC, FMEA, Printing Defect UMKM 268ID Clothing merupakan usaha konveksi dan sablon kaos custom dengan metode Direct transfer film (DTF) yang masih menghadapi tingginya tingkat kecacatan produk. Berdasarkan data produksi periode Januari–September 2025, tingkat kecacatan mencapai 8,94%, melebihi batas toleransi perusahaan sebesar 3%, sehingga proses produksi belum terkendali. Penelitian ini bertujuan mengidentifikasi jenis cacat dominan, menganalisis faktor penyebab utamanya, dan merumuskan usulan perbaikan. Metode yang digunakan adalah Six sigma dengan pendekatan DMAIC (Define, Measure, Analyze, Improve, Control). Tahap define mengidentifikasi cacat melalui check sheet, CTQ, dan diagram SIPOC; tahap measure mengukur kapabilitas proses melalui DPMO, level sigma, dan peta kendali P; tahap analyze menentukan prioritas dengan diagram Pareto serta akar penyebab melalui diagram sebab-akibat dan Failure Mode and Effect Analysis (FMEA); tahap improve merumuskan usulan dengan metode 5W+1H; dan tahap control menyusun rencana pengendalian (Control Plan). Hasil penelitian menunjukkan dua cacat dominan, yaitu posisi sablon tidak presisi (42,19%) dan sablon terkelupas (29,96%) dengan kontribusi kumulatif 72,15%. Proses berada pada level sigma 3,22 dengan rata-rata DPMO 433.59 yang menunjukkan kapabilitas masih rendah, dan seluruh titik peta kendali P berada dalam batas kendali sehingga kecacatan bersifat common cause. Usulan perbaikan yang dirumuskan meliputi penggunaan penggaris DTF, penyusunan SOP penempatan dan parameter press, penambahan grid acuan, kalibrasi mesin, serta pelatihan operator, yang dikonsolidasikan dalam SOP dan dijaga melalui Control Plan untuk menekan kecacatan secara berkelanjutan. Kata kunci: Kualitas, Six sigma, DMAIC, FMEA, Cacat Sablon
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