ANALISIS PENGENDALIAN KUALITAS UNTUK MENURUNKAN JUMLAH DEFECT PADA PRODUK DISC BRAKE DENGAN MENGGUNAKAN METODE DMAIC DI PT. YMI (Produksi Disc Brake Motor)

DIYAH, HALIMATUSSA (2021) ANALISIS PENGENDALIAN KUALITAS UNTUK MENURUNKAN JUMLAH DEFECT PADA PRODUK DISC BRAKE DENGAN MENGGUNAKAN METODE DMAIC DI PT. YMI (Produksi Disc Brake Motor). S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

PT. YMI is a motorcycle disc brake manufacturer based in Indonesia. In the disc brake manufacturing process, there are several sections that are passed, namely press, hfpq, machining, and grinding processes. The highest defects in 2019 were produced in the machining process. In 2019, the highest average defect percentage is 0.176% of the company's target defect limit of 0.04. The machining process almost every month exceeds the company's target limit. The method used is DMAIC which aims to determine the highest type of defect machining, find the root of the problem and make repairs. Based on the results of the calculation of the analysis carried out, the highest machining defect type was C Ø outside NG with a percentage of 33.80%. The causes of C Ø outside NG include: the pin chuck wears out quickly and there is no spare chuck, it is difficult to remove broken pins, often setting the pin chuck on a lathe, the bearing shaft is worn, the operator does not clean the pin holder and forgets to rotate the chip. The steps for the improvement are making the chuck pin holder, procuring a stock of the pin removal tool, making a new pin design, ensuring the stability of the chuck spindle, procuring spare chuck spare parts, installing a warning on the machining machine free of grams or dirt. After the improvement, the sigma value increased 1.33% from 4.54 to 5.87. Keywords: DMAIC, Defect, Disc brake, Machining PT. YMI merupakan produsen disc brake sepeda motor yang berada di Indonesia. Dalam proses pembuatan disc brake terdapat beberapa section yang dilewati yaitu proses press, hfpq, machining, dan grinding. Defect tertinggi ditahun 2019 dihasilkan pada proses machining. Pada tahun 2019 persentase rata-rata defect tertinggi 0,176% dari target batas defect perusahaan 0,04. Proses machining hampir setiap bulannya melewati batas target perusahaan. Metode yang digunakan yaitu DMAIC yang bertujuan untuk mengetahui jenis defect machining tertinggi, mencari akar masalah dan melakukan perbaikan. Berdasarkan hasil perhitungan analisis yang dilakukan, diperoleh jenis defect machining tertinggi yaitu C Ø outside NG dengan persentase sebesar 33.80%. Penyebab C Ø outside NG diantaranya: pin chuck cepat aus dan belum adanya chuck cadangan, sulitnya melepas pin patah,sering dilakukan setting pin chuck mesin bubut, bearing shaft sudah aus, operator tidak membersihkan dudukan pin dan lupa memutar chip. Langkah perbaikkannya yaitu membuat chuck pin holder, pengadaan stock alat pencabut pin,membuat design pin baru, memastikan kestabilan spindel chuck, pengadaan spare chuck cadangan, pemasangan warning dimesin machining bebas dari gram atau kotoran. Setelah dilakukan perbaikan membuat nilai sigma meningkat 1.33% dari 4.54 menjadi 5.87. Kata kunci : DMAIC, Defect, Disc brake,Machining

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