Hidayat, Kresna Nur (2025) Implementasi metode dmaic untuk mengurangi scrap canvas treatment melipat pada proses topping calender di plant bias truck pt tga = Implementation of dmaic method to reduce folding scrap in canvas treatment during topping calender process at bias truck plant, pt tga. Bachelor thesis, Universitas Pelita Harapan.
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Abstract
Scrap merupakan sisa produk atau material yang tidak memenuhi standar kualitas
atau spesifikasi yang ditetapkan. Scrap terjadi akibat adanya kegagalan proses
produksi. Kerugian dari produk scrap dapat berupa meningkatnya biaya produksi,
tingkat kualitas dari suatu kinerja proses rendah yang berdampak pada efisiensi dan
produktivitas. Oleh karena itu, diperlukan adanya perbaikan pada proses yang dapat
menyebabkan suatu produk menjadi scrap. Salah satu permasalahan scrap yang
terjadi di PT TGA adalah scrap canvas treatment melipat pada proses topping
calender. Diperlukan perbaikan dengan menggunakan metode DMAIC untuk dapat
membantu mengurangi scrap canvas treatment melipat. Pada metode DMAIC
langkah awal yang dilakukan adalah menentukan critical to quality untuk
mengidentifikasi peluang perbaikan dari permasalahan yang sering terjadi. Langkah
kedua adalah menghitung nilai DPMO untuk mengetahui tingkat sigma dan kinerja
suatu proses. Pada tahapan ketiga yaitu melakukan analisis berdasarkan hasil
temuan di lapangan dengan mencari akar penyebab permasalahan dengan
menggunakan diagram fishbone dan juga analisis 5 Why. Langkah selanjutnya
adalah melakukan perbaikan berdasarkan perencanaan perbaikan dengan analisis
5W+2H, serta hasil analisis menggunakan FMEA sebagai identifikasi berdasarkan
tingkat keparahan dari suatu potensi kegagalan dengan memerhatikan nilai Risk
Priority Number (RPN). Pada tahapan terakhir dari metode DMAIC adalah
melakukan pengendalian seperti monitoring atau pengawasan terhadap perbaikan
yang telah dilakukan dengan menggunakan Checksheet dan standar operasional
prosedur untuk memastikan bahwa perbaikan yang dilakukan dapat terkendali.
Setelah melakukan rangkaian tahapan DMAIC didapatkan nilai sigma sebesar 4,95
mendekati ke level 5-Sigma dari nilai sebelum perbaikannya adalah 4,76. Scrap
setelah perbaikan mengalami penurunan yang cukup signifikan yaitu sebesar
0,0852% dengan presentase sebelum perbaikan sebesar 0,1686%. Selain itu,
presentase scrap juga masuk target KPI sebesar 0,0931%. / Scrap refers to residual products or materials that fail to meet established quality
standards or specifications. Scrap occurs due to failures in the production process.
The losses caused by scrap include increased production costs and reduced process
performance quality, which negatively impact efficiency and productivity. Therefore,
it is essential to improve processes that contribute to scrap generation. One of the
scrap issues at PT TGA involves folded canvas treatment scrap during the topping
calendar process. Improvements were carried out using the DMAIC method to reduce
folded canvas treatment scrap. The first step in the DMAIC method is identifying the
Critical to Quality (CTQ) factors to pinpoint improvement opportunities in recurring
problems. The second step involves calculating the Defects Per Million Opportunities
(DPMO) value to determine the sigma level and process performance. The third stage
includes analyzing field findings to identify the root causes using fishbone diagrams
and the 5 Why analysis. The next step is implementing improvements based on plans
derived from a 5W+2H analysis and utilizing Failure Mode and Effect Analysis
(FMEA) to identify potential failure severity levels by observing the Risk Priority
Number (RPN). The final step in the DMAIC method involves controlling the
implemented improvements through monitoring and supervision using checksheets
and standard operating procedures to ensure the improvements are sustainable.
Following the DMAIC process, the sigma level improved from 4.76 to 4.95,
approaching the 5-sigma level. Scrap was significantly reduced from 0.1686% to
0.0852%, meeting the KPI target of 0.0931%
Item Type: | Thesis (Bachelor) |
---|---|
Creators: | Creators NIM Email ORCID Hidayat, Kresna Nur NIM01039220005 kresnanurh11@gmail.com UNSPECIFIED |
Contributors: | Contribution Contributors NIDN/NIDK Email Thesis advisor Panjaitan, Andry M NIDN20020047 andry.panjaitan@uph.edu |
Uncontrolled Keywords: | Scrap, DMAIC, DPMO, FMEA, Fishbone, 5 Why |
Subjects: | T Technology > T Technology (General) > T55.4-60.8 Industrial engineering. Management engineering |
Divisions: | University Subject > Current > Faculty/School - UPH Karawaci > Faculty of Science and Technology > Industrial Engineering Current > Faculty/School - UPH Karawaci > Faculty of Science and Technology > Industrial Engineering |
Depositing User: | Magang Input |
Date Deposited: | 22 Apr 2025 01:35 |
Last Modified: | 22 Apr 2025 01:35 |
URI: | http://repository.uph.edu/id/eprint/68155 |