INDRIK, INDRIK (2025) ANALISIS PENGENDALIAN KUALITAS PADA PROSES PENGECATAN VALVE DENGAN MENGGUNAKAN METODE DMAIC PADA PT. KOKAI INDO ABADI. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
PT. Kokai Indo Abadi is a manufacturing company engaged in the production of industrial valves. In its production process, the company faces problems in the painting process, where the number of defective products still exceeds the set quality tolerance threshold, which is 3%. This study aims to identify the most dominant types of painting defects and analyze the causative factors. The method used in this study is DMAIC (Define, Measure, Analyze, Improve, Control) and FMEA (Failure Mode and Effect Analysis) tools to determine the potential for failure that has an impact on quality. Based on the results of the analysis, it was found that the most dominant type of defect was cracked paint with a percentage reaching 44%, which was caused by the use of suboptimal painting equipment and lack of cleanliness and maintenance of tools such as spray guns, hoses, and compressors. Another factor is the lack of supervision from the party responsible for the production process. As a solution for improvement, this study recommends two main actions, namely: (1) Preparation of a daily checklist to ensure the condition of the painting equipment is maintained before and after use, and (2) Implementation of a training program for painting operators to improve understanding of standard procedures and equipment maintenance. By implementing these recommendations, it is expected that the level of defects in the painting process can be minimized so that the quality of the final product is more guaranteed. Keywords: Quality Control, DMAIC, FMEA PT. Kokai Indo Abadi merupakan perusahaan manufaktur yang bergerak dalam produksi valve industri. Dalam proses produksinya, perusahaan menghadapi permasalahan pada proses pengecatan, di mana jumlah produk cacat (defect) masih melebihi ambang batas toleransi kualitas yang ditetapkan, yaitu 3%. Penelitian ini bertujuan untuk mengidentifikasi jenis defect pengecatan yang paling dominan serta menganalisis faktor-faktor penyebabnya. Metode yang digunakan dalam penelitian ini adalah DMAIC (Define, Measure, Analyze, Improve, Control) serta tools FMEA (Failure Mode and Effect Analysis) untuk mengetahui potensi kegagalan yang berdampak pada kualitas. Berdasarkan hasil analisis, ditemukan bahwa jenis defect paling dominan adalah cat retak dengan persentase mencapai 44%, yang disebabkan oleh penggunaan peralatan pengecatan yang tidak optimal serta kurangnya kebersihan dan perawatan alat seperti spray gun, selang, dan kompresor. Faktor lainnya adalah kurangnya pengawasan dari pihak yang bertanggung jawab dalam proses produksi. Sebagai solusi perbaikan, penelitian ini merekomendasikan dua tindakan utama, yaitu: (1) Penyusunan daftar periksa (checklist) harian untuk memastikan kondisi peralatan pengecatan tetap terjaga sebelum dan sesudah digunakan, serta (2) Pelaksanaan program pelatihan bagi operator pengecatan untuk meningkatkan pemahaman terhadap prosedur standar dan perawatan alat. Dengan penerapan rekomendasi tersebut, diharapkan tingkat defect pada proses pengecatan dapat diminimalkan sehingga kualitas produk akhir menjadi lebih terjamin. Kata Kunci : Pengendalian Kualitas, DMAIC, FMEA
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