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TUGAS AKHIR
Peningkatan Kualitas Dengan Metode Six Sigma DMAIC Pada
Manufakturing Botol Kaca (Studi Kasus PT.X)
Diajukan guna melengkapi sebagian syarat dalam mencapai gelar
Sarjana Strata Satu (S1)
Disusun Oleh :
Nama : Phungky Boy Shanjaya
NIM : 41612010028
Program Studi : Teknik Industri
PROGRAM STUDI TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS MERCU BUANA
JAKARTA
2016
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KATA PENGANTAR
Assalaamu alaikum, Wr. Wb.
Puji syukur kehadirat Allah SWT, yang telah melimpahkan rahmat dan
hidayah – Nya, memberikan kekuatan dan kekuatan kepada penulis, sehingga
penulis dapat menyelesaikan laporan hasil Tugas Akhir ini tanpa ada suatu
halangan apapun.
Dalam penyususnan laporan Tugas Akhir ini penulis mengambil judul
Peningkatan Kualitas Dengan Metode Six Sigma DMAIC Pada Manufakturing
Botol Kaca (Studi Kasus PT.X)
Pada kesempatan ini penyusun menyampaikan ucapan terima kasih atas
segala bantuan baik moril maupun spirituil kepada :
1. Bapak Ir. M. Kholil, MT, selaku Koordinator Tugas Akhir, kepala program
studi teknik industri dan Dosen Pembimbing , terimakasih atas bimbingan dan
pembelajaran yang diberikan. juga dukungan yang diberikan.
2. Bapak Resa Taruna Suhada, S.Si, MT, Selaku Dosen Pembimbing Akademik
TI UMB angkatan 2012 .
3. Kepada Seluruh Dosen Teknik Industri yang telah banyak memberikan
bimbingan selama masa perkuliahan
4. Kepada kedua orang tua penulis (Ibu-Ayah) yang setiap saat mendoakan dan
memberikan spirit yang luar biasa.
5. Kepada Suhanda, Higit, Viqi, Anisa, Roudhotul, Rahmah, Renanda, Tridesi
dan semua teman–teman Teknik Industri Mercu Buana khususnya angkatan
2012 (Maaf Tidak Semua di sebutkan), terimakasih atas kebersamaannya.
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6. Semua pihak yang belum disebutkan pada poin-poin sebelumnya namun
terlibat dalam proses pelaksanaan penelitian dan pengerjaan laporan.
Dalam penulisan laporan Tugas Akhir ini, penulis menyadari bahwa
laporan ini masih jauh dari sempurna dan masih banyak kekurangan yang belum
bisa penulis lengkapi sehingga belum dapat memenuhi keinginan pembaca.Untuk
itu kritik dan saran yang bersifat membangun selalu penyusun harapan guna
kesempurnaan laporan ini.
Akhirnya semoga laporan ini dapat bermanfaat bagi penyusun pada
khususnya dan bagi pembaca pada umumnya,
Amin….
Wassalaamu alaikum, WR.Wb.
Jakarta, 25 Mei 2016
Penulis
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DAFTAR ISI
LEMBAR PERNYATAAN .................................................................................... ii
LEMBAR PENGESAHAN ................................................................................... iii
ABSTRAK ............................................................................................................. iv
ABSTRACT .............................................................................................................. v
KATA PENGANTAR ........................................................................................... vi
DAFTAR TABEL ................................................................................................ xiii
DAFTAR GAMBAR ........................................................................................... xiv
BAB I PENDAHULUAN ....................................................................................... 1
1.1 Latar Belakang ...................................................................................... 1
1.2 Perumusan Masalah .............................................................................. 3
1.3 Tujuan Penelitian .................................................................................. 3
1.4 Batasan Masalah ................................................................................... 4
1.5 Sistematika Penulisan ........................................................................... 4
BAB II TINJAUAN PUSTAKA ............................................................................. 6
2.1 Definisi Produksi dan Proses Produksi ................................................. 6
2.1.1 Sistem Produksi .......................................................................... 7
2.1.2 Input,Proses, dan Output dalam Manajemen Produksi ............... 8
2.2 Latar Belakang Pengendalian Kualitas ............................................... 10
2.2.1 Pengertian Kualitas ................................................................... 11
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2.2.2 Faktor-Faktor yang Mempengaruhi Kualitas ............................ 12
2.2.3 Konsep Kualitas Pada Industri Manufaktur .............................. 14
2.2.4 Pengertian Pengendalian Kualitas (Quality Control) ............... 15
2.2.5 Tujuan Pengendalian Kualitas .................................................. 18
2.2.6 Langkah-langkah Pengendalian Mutu ...................................... 21
2.3 Pengertian Six Sigma .......................................................................... 24
2.3.1 Sejarah Six Sigma ..................................................................... 25
2.3.2 Aktivitas Six Sigma .................................................................. 27
2.3.3 Konsep Six Sigma ..................................................................... 27
2.3.4 Beberapa Istilah dalam Six Sigma ............................................ 29
2.3.5 Pihak – pihak yang Terlibat ...................................................... 31
2.3.6 Tahapan Six Sigma .............................................................................. 33
2.3.6.1 Tahap Define ............................................................................. 33
2.3.6.2 Tahap Measure ......................................................................... 35
2.3.6.3 Tahap Analyze ........................................................................... 37
2.3.6.4 Tahap Improve .......................................................................... 40
2.3.6.5 Tahap Control ........................................................................... 41
2.4 Alat bantu yang digunakan dalam six sigma ...................................... 41
2.4.1. Statistical Proces Control (SPC) .............................................. 42
2.4.2. Definisi tentang Data dalam Konteks SPC ............................... 43
2.4.3. Peta Kendali (Control Chart) ................................................... 44
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2.4.4. Peta Kendali Variabel ............................................................... 47
2.4.5. Peta Kendali Atribut ................................................................. 47
2.4.6. Diagram Kualitas ...................................................................... 50
2.4.7. Diagram sebab akibat (Cause of Effect Diagram/Fishbone) .... 51
2.4.8. Metode Failure Mode and Effect Analysis (FMEA) ................ 53
2.5 Penelitian Sebelumnya ........................................................................ 65
2.6 Kerangka Pemikiran ........................................................................... 70
BAB III METODOLOGI PENELITIAN.............................................................. 71
3.1 Rumusan Masalah ............................................................................... 71
3.2 Studi Literatur ..................................................................................... 71
3.3 Pengumpulan Data .............................................................................. 72
3.4 Pengolahan dan Analisa Data ............................................................. 72
3.4.1 Tahap Define ............................................................................. 72
3.4.2 Tahap Measure ................................................................................ 73
3.4.3 Tahap Analyze ........................................................................... 73
3.4.4 Tahap Improve .......................................................................... 73
3.4.5 Tahap Control ........................................................................... 73
3.5 Kesimpulan dan Saran ........................................................................ 74
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA ................................ 76
4.1 Profil Perusahaan ................................................................................ 76
4.1.1 Sejarah Singkat Perusahaan ...................................................... 76
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4.1.2 Visi dan Misi Perusahaan ......................................................... 77
4.1.3 Struktur Organisasi ................................................................... 78
4.1.4 Tenaga Kerja ............................................................................. 84
4.1.5 Waktu Kerja .............................................................................. 84
4.1.6 Kegiatan Produksi Perusahaan ................................................. 85
4.2 Pengumpulan Data .............................................................................. 87
4.2.1 Jenis-Jenis Cacat Produk .......................................................... 87
4.3 Pengolahan Data ................................................................................. 90
4.3.1. Tahap Define ............................................................................. 90
4.3.2. Tahap Measure ......................................................................... 96
4.3.3. Tahap Analyze ........................................................................... 98
4.3.4. Tahap Improve ........................................................................ 105
4.3.5. Tahap Control ......................................................................... 110
BAB V HASIL DAN ANALISA ........................................................................ 112
5.1 Tahap Define ..................................................................................... 112
5.2 Tahap Measure ................................................................................. 114
5.3 Tahap Analyze ................................................................................... 115
5.4 Tahap Improve .................................................................................. 117
5.5 Tahap Control ................................................................................... 117
BAB VI KESIMPULAN DAN SARAN ............................................................ 120
6.1 Kesimpulan ....................................................................................... 120
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6.2 Saran ................................................................................................. 121
DAFTAR PUSTAKA ......................................................................................... 122
LAMPIRAN ........................................................................................................ 125
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DAFTAR TABEL
Tabel 2. 1 Tingkatan Sigma ................................................................................... 25
Tabel 2. 2 Rumus peta kendali ............................................................................... 48
Tabel 2. 3 Severity / Kegawatan ............................................................................ 59
Tabel 2. 4Occurence .............................................................................................. 61
Tabel 2. 5Detection ................................................................................................ 62
Tabel 2. 6 Jurnal Penelitian .................................................................................... 65
Tabel 4. 1 Hasil Produksi ...................................................................................... 87
Tabel 4. 2 Jumlah cacat bulan september.............................................................. 94
Tabel 4. 3 Jumlah cacat bulan oktober .................................................................. 95
Tabel 4. 4 Jumlah cacat bulan november .............................................................. 95
Tabel 4. 5 Tabel konversi sigma ........................................................................... 96
Tabel 4. 6 Hasil perhitungan DPMO dan SQL ..................................................... 97
Tabel 4. 7 Hasil perhitungan yield ........................................................................ 98
Tabel 4. 8 Perhitungan pareto bulan september .................................................... 99
Tabel 4. 9 Perhitungan pareto bulan oktober ...................................................... 100
Tabel 4. 10 Perhitungan pareto bulan november ................................................ 101
Tabel 4. 11Failure Mode and Effects Analysis ................................................... 107
Tabel 4. 12 Usulan penerapan perbaikan ............................................................ 108
Tabel 4. 13 Rekomendasi Scorecard .................................................................. 111
Tabel 5. 1 Hasil Perhitungan Yield ...................................................................... 115
Tabel 5. 2 Hasil persentase cacat ........................................................................ 115
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DAFTAR GAMBAR
Gambar 2. 1 Aliran Input, Proses, Ouput ................................................................ 8
Gambar 2. 2 Perspektif Kualitas ........................................................................... 15
Gambar 2. 3 Keterangan pergeseran sigma........................................................... 28
Gambar 2. 4 Tahapan Six Sigma ........................................................................... 33
Gambar 2. 5 Tampilan Peta Kendali ..................................................................... 46
Gambar 2. 6 Diagram Alir Peta Kendali ............................................................... 47
Gambar 2. 7 Diagram Pareto ................................................................................. 51
Gambar 2. 8 Diagram Sebab Akibat ..................................................................... 53
Gambar 2. 9 Kerangka Pemikiran ......................................................................... 70
Gambar 3. 1 Flowchart penelitian ......................................................................... 75
Gambar 4. 1 Struktur Organisasi ........................................................................... 79
Gambar 4. 2 Aliran Proses Produksi ..................................................................... 86
Gambar 4. 3 Produk botol energy drink ................................................................ 87
Gambar 4. 4 Jenis-jenis Cacat ............................................................................... 89
Gambar 4. 5 Diagram SIPOC ............................................................................... 92
Gambar 4. 6 Critical to Quality ............................................................................. 94
Gambar 4. 7 Diagram Pareto bulan september ..................................................... 99
Gambar 4. 8 Pareto Bulan September dengan Minitab ....................................... 100
Gambar 4. 9 Diagram pareto bulan oktober ........................................................ 101
Gambar 4. 10 Pareto Bulan Oktober dengan Minitab ......................................... 101
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Gambar 4. 11 Diagram pareto bulan november .................................................. 102
Gambar 4. 12 Pareto Bulan November dengan Minitab ..................................... 102
Gambar 4. 13 Cacat Scabby Bottom ................................................................... 103
Gambar 4. 14 Diagram sebab akibat ................................................................... 105
Lampiran 1. 1 Hasil wawancara penentuan FMEA ........................................... 125
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