WIJAYA, PANDU (2025) STRATEGI KEBERLANJUTAN BERBASIS PENINGKATAN PRODUKTIVITAS MELALUI PENGURANGAN REJECT PADA PABRIK MAKANAN OLAHAN BEKU. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
This study aims to formulate a sustainability strategy to increase productivity by reducing the reject rate at PT. XYZ, which consistently exceeds the internal target of 0.75% per month. Using an explanatory sequential mixed-methods design (QUAN → qual), production data from January 2023 to May 2025 were analyzed quantitatively using Statistical Process Control (p-chart) and Pareto diagrams, and qualitatively through Root Cause Analysis (Fishbone Diagram and 5W+1H) validated via Focus Group Discussion (FGD). The p-chart analysis indicates that the production process is statistically unstable, with 10 out of 29 monthly data points exceeding the Upper Control Limit (UCL). The Pareto analysis identified that 21.87% of the total reject volume is concentrated in three main priority products: Potato Fritters, Churros, and Grilled Chicken Gyoza. Qualitative findings validated through FGD confirmed three main root causes: a reactive machine maintenance strategy, a bottleneck in the frying process, and the absence of formalized operator competency standards. Based on these findings, a strategy recommendation based on the Lean Six Sigma (DMAIC) framework was formulated, including a structured implementation plan, Persons in Charge (PICs), and Key Performance Indicators (KPIs) to reduce the reject rate by ≥30% within 6 months and sustainably achieve the ≤0.75% target.. Keywords: P-chart, Pareto, Fishbone, Lean Six Sigma, Product Reject, Frozen Food Industry. Penelitian ini bertujuan merumuskan strategi keberlanjutan untuk meningkatkan produktivitas melalui pengurangan tingkat reject di PT. XYZ, yang secara konsisten melampaui target internal sebesar 0,75% per bulan. Dengan menggunakan desain metode campuran sekuensial eksplanatoris (KUAN → kual), data produksi dari Januari 2023 hingga Mei 2025 dianalisis secara kuantitatif menggunakan Statistical Process Control (p-chart), diagram Pareto, dan secara kualitatif melalui Root Cause Analysis (Diagram Fishbone dan 5W+1H) yang divalidasi melalui Focus Group Discussion (FGD). Hasil analisis p-chart menunjukkan bahwa proses produksi berada dalam kondisi tidak stabil secara statistik, dengan 10 dari 29 titik data bulanan melampaui Batas Kendali Atas (Upper Control Limit - UCL). Analisis Pareto mengidentifikasi bahwa 21,87% dari total volume reject terkonsentrasi pada tiga produk prioritas utama: Perkedel Kentang, Churos, dan Gyoza Ayam (Grill). Temuan kualitatif yang divalidasi melalui FGD menegaskan tiga akar penyebab masalah utama: strategi perawatan mesin yang masih reaktif, adanya bottleneck pada proses penggorengan (frying), dan ketiadaan standar kompetensi operator yang terformalisasi. Berdasarkan temuan tersebut, dirumuskan rekomendasi strategi berbasis kerangka Lean Six Sigma (DMAIC) yang mencakup rencana implementasi terstruktur, penanggung jawab (PIC), dan Indikator Kinerja Utama (KPI) untuk menurunkan tingkat reject sebesar ≥30% dalam 6 bulan dan mencapai target ≤0,75% secara berkelanjutan. Kata Kunci: P‑ chart, Pareto, Fishbone, Lean Six Sigma, Produk reject, industri makanan beku.
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