Perbaikan Proses Produksi Granule dengan Metode Lean Six-Sigma untuk Mengurangi Pemborosan di PT X

Wawan Kurniawan; Zulfahmi Zulfahmi; Ratna Mira Yojana

doi:10.56211/factory.v4i3.1657

Authors

Wawan Kurniawan Universitas Trisakti
Zulfahmi Universitas Trisakti
Ratna Mira Yojana Universitas Trisakti

DOI:

https://doi.org/10.56211/factory.v4i3.1657

Keywords:

DMAIC; Granule; Lean Six Sigma; VSM

Abstract

Penelitian ini dilakukan di PT X yang merupakan perusahaan manufaktur pada industri arang. Permasalahan yang dimiliki perusahaan adalah ketidaktercapaian target produksi dan persentase cacat yang tinggi. Tujuan penelitian adalah meminimalkan pemborosan dan meningkatkan kualitas produk. Metode yang digunakan adalah pendekatan Lean Six Sigma. Tahapan penelitian mengikuti tahapan DMAIC (Define, Measure, Analysis, Improve, Control). Tahap define dilakukan untuk mengidentifikasi permasalahan menggunakan diagram SIPOC dan CTQ. Tahapan measure dilakukan untuk mengukur kapabilitas proses menggunakan peta kendali, perhitungan DPMO, dan nilai sigma, kemudian membuat peta VSM. Nilai DPMO yang didapatkan adalah 9992.957 dan tingkat sigma 3,8. Melalui VSM diketahui bahwa MLT untuk proses pembuatan granule adalah 8174.553 detik dan nilai PCE sebesar 36.77%. Tahapan selanjutnya menganalisis menggunakan diagram Ishikawa dan FMEA. Hasil analisis menunjukkan bahwa penyebab permasalahan berupa kualitas bahan baku yang kurang baik, pemeriksaan bahan baku yang buruk, dan kerusakan pada mesin. Sehingga pada tahap improve diusulkan perbaikan berupa lembar kerja pemeriksaan bahan baku, pemeriksaan berkala pada mesin, penambahan alat pemisah logam dan penambahan mesin untuk proses pembakaran. Tahap control dilakukan dengan pengisian lembar pemeriksaan bahan baku dan mesin secara berkala.

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