PERBAIKAN KUALITAS DEFECT WASHER DENGAN PENDEKATAN PDCA DAN KAIZEN DI PT. MW

MUSTAQIM, WAHID (2020) PERBAIKAN KUALITAS DEFECT WASHER DENGAN PENDEKATAN PDCA DAN KAIZEN DI PT. MW. S1 thesis, Universitas Mercu Buana Bekasi.

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Abstract

iv ABSTRACT Quality is one important factor determining the success of a company in mastering competition. In the process of stamping PT. MW, quality is measured through Ppm (Part Per Million), which is a graph of defects that occur at the Stamping plant. In 2019, the Ppm has not yet reached the specified target. One of the defects that contributed greatly to the Ppm is the type of defect bury. The study was conducted using Kaizen through the PDCA cycle. It is known that there are four root causes of defect burry: The condition of the arrangement of parts which are not neat, setting the parameters of the machine that changes due to the displacement of the machine, checking method by man power or operator ie not checking the dimensions periodically, Human or man power that is not stable at one machine will move the engine so that the man power is always new. By making improvements in accordance with the root of the problem that has been found, the result was defect washer clevis reduced by 57.1%. Standards are set to support the progress of the repairs carried out, namely the work standards of how to arrange parts on the box with neat arrangement to ensure the parts are not scratched with other parts when there is a part moving activity, the standard maintenance of stopper dies parameters on dies stamping so that the parameters remain stable, quality standards or Q Point to ensure that man power understands the quality standards of parts that are being made, and the maintenance standards for jig inspection. Keywords: defect; washer; stamping; ABSTRAK Kualitas merupakan salah satu faktor penting penentu keberhasilan suatu perusahaan dalam menguasai persaingan. Pada proses Stamping PT. MW, kualitas diukur melalui Ppm (Part Per Millon), yaitu dengan grafik defect yang terjadi pada plant Stamping. Pada tahun 2019, Ppm belum mencapai target yang ditentukan. Salah satu defect yang berkontribusi besar terhadap Ppm adalah jenis defect bury. Penelitian dilakukan dengan menggunakan Kaizen melalui siklus PDCA. Diketahui bahwa terdapat empat akar penyebab defect burry : Kondisi penyusunan part yang tidak rapih, settingan parameter mesin yang berubah-ubah dikarenakan perpindahan mesin, metode pengecekan oleh man power atau operator yaitu tidak dilakukannnya pengecekan dimensi secara berkala, Manusia atau man power yang tidak stanby di satu mesin akan tetapi berpindah-pindah mesin sehingga man power selalu baru. Dengan melakukan perbaikan sesuai dengan akar permasalahan yang telah ditemukan, didapatkan hasil defect washer clevis berkurang sebanyak 57.1%. Ditetapkan standar untuk mendukung berjalannya perbaikan yang dilakukan, yaitu standar kerja cara penyusunan part pada box dengan penyusunan rapih untuk memastikan part tidak tergores dengan part yang lain ketika terjadi aktivitas pemindahan part, standar perawatan stopper dies parameter pada dies stamping sehingga parameter tetap stabil, standar kualitas atau Q Point untuk memastikan man power paham akan standar kualitas part yang sedang di buat, serta standar perawatan jig inspection. Kata Kunci: defect; washer; stamping;

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