PENERAPAN KONSEP KAIZEN UNTUK MENGURANGI DOWNTIME SETUP AND ADJUSTMENT PADA PRODUK ROTOR DENGAN MENGGUNAKAN METODE DMAIC (STUDI KASUS: PERUSAHAAN COMPRESSOR AC)

ZAELANI, MOHAMAD ZAMZAM (2025) PENERAPAN KONSEP KAIZEN UNTUK MENGURANGI DOWNTIME SETUP AND ADJUSTMENT PADA PRODUK ROTOR DENGAN MENGGUNAKAN METODE DMAIC (STUDI KASUS: PERUSAHAAN COMPRESSOR AC). S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

In the industrial sector, production process efficiency plays a crucial role in reducing costs and enhancing productivity. This study aims to minimize downtime caused by Setting tool activities on the Rotor machining 5A OP 20 line at an air compressor manufacturing company. The approach combines the continuous Improvement philosophy of Kaizen with the structured DMAIC (Define, Measure, Analyze, Improve, Control) methodology from Six Sigma .Data revealed that Setting tool activities contributed to 3.08% of total downtime, exceeding the company’s target of 2.00%. Through primary and secondary data collection and quantitative analysis, this research identified several root causes, including suboptimal tool lifetime, inappropriate Cutting Parameters, and the absence of standardized operating procedures. Interventions were carried out by improving tool specifications, developing SOPs, conducting operator training, and visualizing production data. As a result, downtime was reduced by 27.7%, tool lifetime increased by 10%, and estimated Cost Savings reached IDR 41.654.021,81 per years. Beyond technical achievements, the study demonstrates that cross-functional collaboration and active employee involvement in the Improvement process foster a more efficient, adaptive, and sustainable work culture. The integration of Kaizen principles supported by the DMAIC framework proves to be an effective strategy for enhancing operational efficiency and achieving comprehensive cost reduction in the manufacturing sector. Keywords: Kaizen, DMAIC, Downtime, Setting tool, Cost Reduction Dalam bidang industri efisiensi proses produksi menjadi kunci utama dalam menekan biaya dan meningkatkan produktivitas. Penelitian ini bertujuan untuk mengurangi downtime yang terjadi akibat aktivitas Setting tool pada lini Rotor machining 5A OP 20 di perusahaan manufaktur kompresor AC. Pendekatan yang digunakan mengombinasikan filosofi perbaikan berkelanjutan Kaizen dengan metode terstruktur DMAIC (Define, Measure, Analyze, Improve, Control) dari Six Sigma .Data menunjukkan bahwa aktivitas Setting tool menyumbang downtime sebesar 3,08%, melebihi target perusahaan sebesar 2,00%. Melalui pengumpulan data primer dan sekunder, serta analisis kuantitatif, penelitian ini berhasil mengidentifikasi akar permasalahan utama, antara lain belum optimalnya Lifetime Tool, ketidaksesuaian parameter pemotongan, serta belum adanya standarisasi prosedur kerja. Intervensi dilakukan melalui peningkatan spesifikasi tool, penyusunan SOP, pelatihan operator, dan visualisasi data produksi. Hasilnya, downtime berhasil dikurangi sebesar 27,7%, Lifetime Tool meningkat 10%, dan estimasi penghematan biaya mencapai Rp41.654.021,81 Per Tahun. Lebih dari sekadar pencapaian teknis, penelitian ini menunjukkan bahwa kolaborasi antar tim serta keterlibatan aktif karyawan dalam proses perbaikan mampu menciptakan budaya kerja yang lebih efisien, adaptif, dan berkelanjutan. Penerapan konsep Kaizen yang didukung oleh kerangka kerja DMAIC terbukti menjadi strategi efektif dalam meningkatkan efisiensi dan mendukung pencapaian tujuan cost reduction secara menyeluruh di sektor manufaktur. Kata Kunci: Kaizen, DMAIC, Downtime, Setting tool, Cost Reduction

Item Type:	Thesis (S1)
Call Number CD:	FT/IND. 25 071
NIM/NIDN Creators:	41621110046
Uncontrolled Keywords:	Kaizen, DMAIC, Downtime, Setting tool, Cost Reduction
Subjects:	600 Technology/Teknologi > 650 Management, Public Relations, Business and Auxiliary Service/Manajemen, Hubungan Masyarakat, Bisnis dan Ilmu yang Berkaitan > 658 General Management/Manajemen Umum > 658.3 Personnel Management/Manajemen Personalia, Manajemen Sumber Daya Manusia, Manajemen SDM 600 Technology/Teknologi > 670 Manufacturing/Manufaktur, Pabrik-pabrik 600 Technology/Teknologi > 690 Buildings/Teknik Bangunan > 697 Heating, ventilating, air-conditioning engineering/Teknik Pemanasan Rumah, Teknik Pemanas Ruangan, Teknik Ventilasi dan Pendingin Ruangan AC 700 Arts/Seni, Seni Rupa, Kesenian > 750 Painting and Paintings/Seni Lukis dan Lukisan > 758 Other Subjects/Subjel Lainnya > 758.6 Industrial and Technical Subjects/Subjek Industri dan Teknik
Divisions:	Fakultas Teknik > Teknik Industri
Depositing User:	khalimah
Date Deposited:	29 Aug 2025 09:19
Last Modified:	29 Aug 2025 09:19
URI:	http://repository.mercubuana.ac.id/id/eprint/97277

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