PRAYUDHA, RIZAL ARDI IRIYANTO (2019) ANALISIS PERBAIKAN KUALITAS DENGAN PENDEKATAN SIX SIGMA (DMAIC) UNTUK MENGURANGI JUMLAH DEFECT PADA PRODUK COVER CRANK CASE DI PT. TAKAGI SARI MULTI UTAMA. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
PT. Takagi Sari Multi Utama is an organization engaged in manufacturing plastic injection, one of the products produced is the Cover Crank Case. The company produces a defect in the Cover Crank Case production for the period March 2018 - August 2018 of 1.99% while the tolerance limit of the company is only 1% which has a difference of 0.99%. This study aims to reduce the number of defects by providing recommendations for improvement. The method used is DMAIC (Define, Measure, Analyze, Improve, Control) by calculating the company's sigma value and using FMEA (Failure Mode and Effect Analysis) tools to provide recommendations for improvement proposals for urgent problems to be repaired. Define Phase makes SIPOC diagrams and identifies VOC (Voice of Customer) to determine the description of CTQ (Critiqal To Quality). At the Measure stage, the results of the calculation of the sigma value obtained by DPMO amounted to 766.7452117 with a sigma value of 4.67. The most dominant type of defect cover Crank Case product is Scrap Awal Loss based on the results of the analysis using Pareto Diagrams at the Analyze stage and obtained the causes of Scrap Awal Loss defects using Fishbone Diagram. In the Improve stage, the calculation of FMEA obtained the factors causing the most potential problems, namely engine stopping with a RPN (Risk Priority Number) value of 144 so that it becomes a priority for improvement. Changing the resting time for the operator by creating a group method so that the machine can carry out continuous production and adding human resources to support the applied method as an alternative to the proposed improvement and elaborated through the analysis of 5W + 1H at the Improve stage. Then the control proposal is given to avoid the emergence of new problems at the Control stage. Keywords: Cover Crank Case, Quality, Defect, DMAIC, Six Sigma, FMEA. PT. Takagi Sari Multi Utama merupakan sebuah organisasi yang bergerak dibidang manufaktur injection plastic, salah satu produk yang dihasilkan adalah Cover Crank Case. Perusahaan memproduksi defect pada produksi Cover Crank Case periode Maret 2018 – Agustus 2018 sebesar 1,99% sedangkan batas toleransi dari perusahaan hanya sebesar 1% yang mana terdapat selisih 0,99%. Penelitian ini bertujuan untuk menekan jumlah defect dengan memberikan rekomendasi usulan perbaikan. Metode yang digunakan adalah DMAIC (Define, Measure, Analyze, Improve, Control) dengan menghitung nilai sigma perusahaan serta menggunakan tools FMEA (Failure Mode and Effect Analysis) untuk memberikan rekomendasi usulan perbaikan terhadap permasalahan yang mendesak untuk dilakukan perbaikan. Tahap Define membuat diagram SIPOC serta mengindentifikasi VOC (Vioce Of Customer) untuk menentukan deskripsi dari CTQ (Critiqal To Quality). Pada tahap Measure, hasil perhitungan nilai sigma diperoleh DPMO sebesar 766,7452117 dengan nilai sigma sebesar 4,67. Jenis defect paling dominan produk Cover Crank Case adalah Scrap Awal Loss berdasarkan hasil analisis menggunakan Pareto Diagram di tahap Analyze serta diperoleh penyebab defect Scrap Awal Loss menggunakan Fishbone Diagram. Pada tahap Improve, perhitungan FMEA diperoleh faktor penyebab permasalahan yang paling potensial yaitu pemberhentian mesin dengan nilai RPN (Risk Priority Number) sebesar 144 sehingga menjadi prioritas untuk dilakukan perbaikan. Melakukan pergantian waktu istirahat pada operator dengan cara membuat metode grup agar mesin bisa melakukan produksi secara kontinyu dan menambah sumber daya manusia untuk menunjang metode yang diterapkan menjadi alternatif usulan perbaikan dan dijabarkan melalui analisis 5W+1H pada tahap Improve. Selanjutnya diberikan usulan pengendalian untuk menghindari timbulnya maslaah baru pada tahap Control. Kata Kunci: Cover Crank Case, Kualitas, Defect, DMAIC, Six Sigma, FMEA
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