ANALISIS PROSES ASSEMBLY GREEN TIRE UNTUK MENGURANGI SCRAP IN PROCESS MENGGUNAKAN METODE DMAIC PADA PERUSAHAAN MANUFAKTUR BAN KENDARAAN DI KOTA TANGERANG

ALBIANSYAH, YUSA (2023) ANALISIS PROSES ASSEMBLY GREEN TIRE UNTUK MENGURANGI SCRAP IN PROCESS MENGGUNAKAN METODE DMAIC PADA PERUSAHAAN MANUFAKTUR BAN KENDARAAN DI KOTA TANGERANG. S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

PT. IR is a motorcycle tire manufacturing company in the city of Tangerang. In the production process in addition to producing products there are materials for production that do not have a value or which can be called scrap in process. The production department is challenged by management to reduce scrap in process. Based on the average data of 2021, Scrap Canvas is the highest scrap and the building department is the highest contributor to the Canvas scrap. The average scrap Canvas January-March 2022 period is 0.61% while the target set by management is 0.45%. This study aims to determine the highest type of scrap Canvas, and the implementation of improvements to the main causes of scrap Canvas in the Assembly Green Tire process. DMAIC (Define, Measure, Analyse, Improve, Control) is a method used in this study. The results of the analysis showed the Canvas scrap to the highest scrap with a percentage of 81%. Based on the Fishbone Diagram, the main cause of the Canvas scrap is a material tearing process with the operator's hand causing dimensional changes due to the pull, the lack of operator's concern for the scrap, the point of stopping drums that rotate inaccurate. The improvement action taken was the use of a knife for the material tearing method, the socialization accompanied by a random check conducted by the leader, the addition of the drum rotation program. The results showed a decrease in the previous 6,180 DPMO value to 2,357, so the Sigma level increased 8.25% from the previous 4.00 to 4.33. The previous percentage of scrap was 0.66% down to 0.24%. The decline in the number of scraps reduced the company's loss by Rp227,425.02. Keyword: DMAIC, Six Sigma, scrap, Canvas PT. IR merupakan perusahaan manufaktur ban sepeda motor yang berada di Kota Tangerang. Dalam proses produksi selain menghasilkan produk terdapat bahan sisa produksi yang tidak memiliki nilai guna atau yang bisa disebut sebagai scrap in process. Departemen produksi mendapat tantangan dari manajemen untuk menurunkan scrap in process. Berdasarkan data rata-rata tahun 2021, scrap Canvas merupakan scrap tertinggi dan departemen building menjadi penyumbang scrap Canvas tertinggi. Rata-rata scrap Canvas priode Januari-Maret 2022 sebesar 0.61% sedangkan target yang ditetapkan manajemen sebesar 0,45%. Penelitian ini bertujuan untuk mengetahui jenis scrap Canvas tertinggi,dan implementasi perbaikan terhadap penyebab utama munculnya scrap Canvas pada proses assembly Green Tire. DMAIC (Define, Measure, Analyze, Improve, Control) merupakan metode yang digunakan dalam penelitian ini. Hasil analisis menunjukan scrap sobekan Canvas menjadi scrap tertinggi dengan presentase sebesar 81%. Berdasarkan fishbone diagram penyebab utama scrap sobekan Canvas yaitu proses penyobekan material dengan tangan operator menyebabkan perubahan dimensi akibat adanya tarikan, minimnya kepedulian operator terhadap scrap, titik henti drum yang berputar tidak akurat. Tindakan perbaikan yang dilakukan yaitu penggunaan pisau untuk metode penyobekan material, sosialisasi disertai random check yang dilakukan oleh leader, penambahan program putaran drum. Hasil penelitian menunjukkan penurunan pada nilai DPMO yang sebelumnya 6.180 menjadi 2.357, sehingga level Sigma mengalami peningkatan 8.25% dari yang sebelumnya 4,00 menjadi 4,33. Persentase scrap yang sebelumnya 0.66% turun menjadi 0.24%. Penurunan jumlah scrap tersebut mengurangi kerugian perusahaan sebesar Rp227.425.02. Kata kunci: DMAIC, Six Sigma, scrap, Canvas

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