Implementasi Metode Six Sigma Untuk Mereduksi Cacat Pada Produksi Sendok Premium (Studi Kasus PT. ABC)

Kadex Widhy Wirakusuma, Kadriadi Kadriadi, Ari Pranata Primisa Purba

Abstract


PT ABC is a company in the manufacturing industry that produces premium spoons. The raw material used is 304 stainless steel. The high volume of defective production impacts reducing the level of customer satisfaction so that it indirectly causes losses to the company. The maximum defect rate determined and allowed by the company is 4.25% of total production. This study aims to determine critical defects and provide alternative improvements to reduce the level of product defects and increase the sigma level in making premium spoons. In this study, the Six Sigma method is used to determine the sigma level to be used as a reference in making corrective actions; the existing condition shows that the sigma level is 4.29, indicating that corrective steps need to be taken. The results showed that by analyzing Pareto diagrams, three critical defects occurred in spoon products: warping 98 pieces, freckles 102 pieces, and Discoloration 99 pieces. The root Cause Analysis method is used to identify factors that cause defects in spoons. The FMEA method is used to provide alternative improvements by reducing the potential for failure by considering the RPN value, where the RPN value of warping defects is 60, the RPN value of freckles defects is 60, and the highest RPN value obtained by Discoloration defects is 64. At the improvement stage, alternative improvements are given; from the proposed improvements, a decrease in the number of defects is obtained, which for warping defects is 15.5%, freckles are 16%, and Discoloration is 12.8% with a total decrease in the number of defects is 44.3%. From the results of the improvements that have been implemented, the DPMO value is 7,800 with a sigma level of 4.74.

 

PT ABC adalah sebuah perusahaan dibidang industri manufaktur yang memproduksi sendok premium. Bahan baku yang digunakan yaitu stainless steel 304. Tingginya volume produksi yang cacat berdampak pada menurunnya tingkat kepuasan konsumen sehingga secara tidak langsung menimbulkan kerugian bagi perusahaan. Tingkat kecacatan maksimum yang telah ditentukan dan diizinkan perusahaan adalah 4,25% dari total produksi. Penelitian ini bertujuan untuk mengetahui cacat kritis dan memberikan alternatif perbaikan yang dilakukan sebagai upaya untuk menurunkan tingkat cacat produk serta meningkatkan level sigma pada proses pembuatan sendok premium. Pada penelitian ini metode Six Sigma digunakan untuk mengetahui level sigma sehingga dapat dijadikan sebagai acuan dalam membuat tindakan perbaikan, kondisi eksisting menunjukkan bahwa level sigma bernilai 4,29, kondisi ini menunjukkan perlu dilakukan langkah perbaikan. Hasil penelitian menunjukkan bahwa dengan melakukan analisis diagram pareto terdapat 3 jenis cacat kritis yang terjadi pada produk sendok: warping 98 buah, freckles 102 buah, dan Discoloration 99 buah. Metode Root Cause Analysis digunakan untuk mengidentifikasi faktor yang menjadi penyebab terjadinya cacat pada sendok. Metode FMEA digunakan untuk memberikan alternatif perbaikan dengan mereduksi potensi terjadinya kegagalan dengan mempertimbangkan nilai RPN, di mana nilai RPN cacat warping adalah sebesar 60, nilai RPN cacat freckles adalah sebesar 60 dan nilai RPN tertinggi diperoleh oleh cacat Discoloration adalah sebesar 64. Pada tahapan improve diberikan alternatif perbaikan, dari usulan perbaikan diperoleh tingkat penurunan jumlah cacat yang di mana untuk cacat warping sebesar 15,5%, freckles adalah sebesar 16%, dan Discoloration sebesar 12,8% dengan total nilai penurunan jumlah cacat adalah 44,3%. Dari hasil perbaikan yang sudah diterapkan, diperoleh nilai DPMO sebesar 7.800 dengan level sigma bernilai sebesar 4.74.


Keywords


Six Sigma; DMAIC; RCA; FMEA; Defect

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DOI: https://doi.org/10.35194/jmtsi.v7i2.2728

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