RAHAYU, GHINA (2022) ANALISIS PENGENDALIAN KUALITAS PADA PRODUK WASHER STEM NUT PADA DIVISI STAMPING DENGAN MENGGUNAKAN METODE DMAIC DI PT. MADA WIKRI TUNGGAL PLANT 1. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
PT. Mada Wikri Tunggal is a company engaged in metal and plastic components. PT. Mada Wikri is a company that supplies spare parts to various companies in Indonesia. One of them is PT. Astra Honda Motor (AHM). In the manufacture of spare parts made from metal components, a process called stamping, welding, and machining is carried out. Among the three processes, the stamping process produces the highest internal reject. The Stamping process processes parts for more than 300 types of items, but of all the parts produced in the Stamping Division, this Washer Stem Nut product often has the most internal rejects. The average percentage of internal rejects from September 2021 to February 2022 reached 3.5% of the internal reject limit target set by the company of 2.5%. This study aims to determine the highest type of defect from washer stem nut, find the root cause of the highest type of defect washer stem nut and implement improvements to the main cause of the highest defect in washer stem nut products. The method used is DMAIC (Define, Measure, Analyze, Improve, Control). The results of the analysis carried out obtained the highest type of stem nut washer defect, which was caused by clots with a percentage of 80.33%. The main causes of clots include: Negligence of material placement that is not parallel to the dies, worn guide rails, checking material by sampling, non-standard when setting the machine, noisy engine noise and lack of air circulation. The implementation of the improvements carried out is to monitor and improve SOPs as a reference for operators, die replacement, increase the frequency of machine inspections and evaluate the preventive maintenance schedule for production machines, especially for machines that are old, as well as regular replacement of spare parts, guidance on work instructions and sheets. monitoring feeder step settings, always socializing to production operators at the beginning of each briefing and shift change. Keywords : DMAIC, Six Sigma, Defect, Stamping PT. Mada Wikri Tunggal merupakan perusahaan yang bergerak dibidang metal dan plastic component. PT. Mada Wikri merupakan perusahaan penyuplai sparepart untuk berbagai perusahaan yang ada di Indonesia. Salah satunya yakni PT. Astra Honda Motor (AHM). Dalam pembuatan sparepart berbahan metal component dilakukan suatu proses yang dinamakan dengan stamping, welding, dan machining. Diantara ketiga proses tersebut, proses stamping yang menghasilkan reject internal tertinggi. Proses Stamping memproses part sebanyak 300 lebih jenis item, namun dari semua part yang di produksi pada Divisi Stamping, produk Washer Stem Nut ini yang sering memiliki reject internal terbanyak. Persentase rata – rata reject intenal dari bulan September 2021 hingga Februari 2022 mencapai 3,5% dari target batas reject internal yang ditetapkan perusahaan sebesar 2,5%. Penelitian ini bertujuan untuk mengetahui jenis defect tertinggi dari washer stem nut, mencari akar masalah dari jenis defect washer stem nut tertinggi dan implementasi perbaikan terhadap penyebab utama munculnya defect tertinggi pada produk washer stem nut. Metode yang digunakan yaitu DMAIC (Define, Measure, Analyze, Improve, Control). Hasil perhitungan analisis yang dilakukan diperoleh jenis defect washer stem nut tertinggi yaitu disebabkan karena gompal dengan persentase sebesar 80,33%. Penyebab utama terjadinya gompal diantaranya: Kelalaian penempatan material yang tidak sejajar dengan dies, Guide rel sudah aus, pengecekan material secara sampling, Tidak standar saat settingan mesin, suara mesin bising serta minimnya sirkulasi udara. Implementasi perbaikan yang dilakukan yaitu melakukan pengawasan dan perbaikan SOP sebagai acuan operator, penggantian dies, meningkatkan frekuensi pemeriksaan mesin serta mengevaluasi jadwal preventive maintenance terhadap mesin produksi, khususnya untuk mesin - mesin yang usianya sudah tua serta adanya penggantian spare part secara berkala, adanya guidance instruksi kerja dan lembar monitoring setting langkah feeder, selalu sosialisasi terhadap operator produksi setiap awal breafing dan pergantian shift. Kata kunci : DMAIC, Six Sigma, Defect, Stamping
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