PERBAIKAN PROSES UNTUK MENGURANGI SCRAP BEAD WIRE DI PT X DENGAN MENGGUNAKAN METODE DMAIC

Sukma, Albhie Riskiyana (2024) PERBAIKAN PROSES UNTUK MENGURANGI SCRAP BEAD WIRE DI PT X DENGAN MENGGUNAKAN METODE DMAIC. Bachelor thesis, Universitas Pelita Harapan.

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Abstract

Scrap merupakan salah satu masalah yang sering timbul dalam proses produksi di PT. X. Sehingga apabila tidak dilakukan perbaikan maka nantinya akan berdampak ke berbagai macam problem diantaranya adalah cost yang semakin tinggi, dan juga keterlambatan pengiriman produk ke next process. Selain itu kecacatan produk atau scrap juga berpengaruh terhadap kepuasan pelanggan. Perbaikan yang dilakukan untuk meminimalisir problem bead wire adalah dengan menggunakan metode DMAIC. Dalam metode DMAIC diawali dengan melakukan penentuan Critical To Quality untuk mengetahui opportunity dari problem yang sering terjadi. Selanjtunya dilakukan proses pengumpulan data dan menentukan perhitungan DPMO, nilai sigma serta pareto diagram dengan tujuan memastikan item mana yang nantinya akan dilakukan proses perbaikan. Selanjutnya dilakukan proses analisa di area proses dan membuat FMEA berkaitan dengan Severity, Occurance, dan Detection. Setelah didapatkan nilai RPN dengan perkalian nilai Severity, Occurance, dan Detection maka langkah selanjutnya adalah melakukan perbaikan berdasarkan nilai RPN tertinggi. Kemudian setelah dilakukan proses perbaikan maka langkah selanjutnya adalah melakukan proses Control dengan membuat checksheet dan juga standar operasional prosedur sehingga nantinya perbaikan bisa dilakukan secara terus menerus. Setelah dilakukan proses perbaikan dengan metode DMAIC maka didapatkan peningkatan nilai sigma dari yang tadiya 4,59 menjadi 4,88 setelah perbaikan, selain itu persentase scrap berdasarkan total produksi juga berhasil diminimalisir menjadi 0,11% atau masih dibawah target yang sudah ditetapkan oleh manajemen yaitu 0,20%. / Scrap is one of the problems that often arises in the production process at PT. X. So that if not repaired, it will have an impact on various kinds of problems including the higher cost, and also the late delivery of products to the Next Process. Apart from that, product defects or scrap also affect customer satisfaction. Improvements made to minimize bead wire problems are by using the DMAIC method. The DMAIC method begins by determining Critical To Quality to identify opportunities for problems that often occur. Next, the data collection process is carried out and determines the DPMO calculation, sigma value and Pareto diagram with the aim of determining which items will later be carried out in the improvement process. Next, an analysis process is carried out in the process area and creates an FMEA related to Severity, Occurance and Detection. After obtaining the RPN value by multiplying the Severity, Occurance and Detection values, the next step is to make improvements based on the highest RPN value. Then, after the repair process has been carried out, the next step is to carry out the Control process by creating checksheets and also standard operating procedures so that improvements can be carried out continuously. After carrying out the improvement process using the DMAIC method, an increase in the sigma value was obtained from 3.5 to 3. After the improvement, apart from that, the percentage of scrap based on total production was also successfully minimized to 0.20% or still below the target set by management.

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