ANALISIS PENGENDALIAN KUALITAS INDUSTRI TEKSTIL DENGAN METODE SIX SIGMA (DMAIC) DI PT. PRIMISSIMA

PINANDITO TUR WICAKSONO, Ir. Janu Pardadi, MT

2014 | Skripsi | TEKNIK INDUSTRI

Pada penelitian yang dilakukan di PT. PRIMISSIMA berfokus pada pengendalian kualitas pada kain grey shuttle loom dengan menggunakan metode six sigma (DMAIC). Analisa dilakukan dengan mengambil data atribut hasil produksi dan jumlah cacat periode Januari 2011 - Juni 2013 di bagian grey finishing. Data yang diperoleh kemudian dianalisa dengan menggunakan metode six sigma dengan menerepkan tahapan-tahapan DMAIC (Define, Measure, Analyze, dan Control). Data kemudian dianalisa sesuai tahapan DMAIC yaitu dengan menentukan jumlah CTQ potensial, diagram pareto, peta kendali. Dengan melihat peta kendali maka akan terlihat proses sudah berada dalam batas kendali atau tidak, bila proses tersebut tidak memenuhi syarat maka akan berada diluar batas kendali disebabkan oleh karena penyebab khusus. Kemudian dilanjutkan dengan analisis ketidaksesuaian dengan menggunakan diagram sebab-akibat, dan disusun rencana perbaikan dengan 5W+1H. Selanjutnya menggunakan metode FMEA untuk mengetahui prioritas tindakan yang diutamakan untuk dilakukan perbaikan. Analisis yang diperoleh dengan menggunakan metode six sigma menunjukkan bahwa proses produksi kain grey shuttle loom masih belum terkendali. Dan dari hasil analisa didapatkan kapabilitas dari sigma sebesar 3,74 dengan DPMO = 12.443, artinya dalam satu juta produk terdapat 12.443 yang mengalami kecacatan. Dan pada perhitungan peta kendali p diperoleh bahwa proses yang dilakukan oleh PT. PRIMISSIMA masih belum stabil, dikarenakan perhitungan peta kendali terdapat 15 data yang masih belum berada dibatas kendali. Kemudian dengan menggunakan metode FMEA diperoleh nilai RPN (Risk Priority Number) = 245, yang merupakan nilai terbesar sehingga dibutuhkan tindakan prioritas A pada equipment yaitu perbaikan yang harus dilakukan sekarang juga. Rekomendasi yang dapat diberikan untuk PT. PRIMISSIMA berdasarkan analisis tersebut adalah dengan cara mengutamakan perawatan pada mesin khususnya pada komponen yang sering mengalami kerusakan. Diharapkan rencana perbaikan tersebut dapat dilaksanakan dan meningkatkan kualitas produk di PT. PRIMISSIMA.

ABSTRACT By the time there is a perspective of consumers that is concern about the product quality, for example the best quality products at low prices. Quality had to be paramount and must be maintained by the company in order to meet the demands of consumers which is very critical and selective. Problems will arise if a company can not control the quality of a product well, the problems that could be emerge such as cost of poor quality, and reduced the loyalty from the consumers to the products. Therefore, this study proposed a quality control system approach six sigma DMAIC method (Define, Measure, Analysis, Improve, and Control) as a technique that can evaluate and control the quality improvement expectations towards zero failure rate (zero defect). Objective to analyze the causes of product defects by methods of six sigma (DMAIC) to reducing defects, and provide recommendations for improvements to the company. This research was conducted in PT . PRIMISSIMA located in Yogyakarta and focusing on improving product quality gray fabric shuttle loom. The analysis obtained by using the six sigma method showed that the shuttle loom gray fabric production is still not under control . And analysis of the results obtained from the sigma capability of 3.74 with DPMO = 12 443 , meaning that in a million there are 12 443 products that have disabilities . And the calculation of control chart showed that UCL = 0.43, CL = 0,41 and LCL = 0.39 . Now we know the value of sigma process, and analyzed using Pareto, and cause-effect diagram, based on Pareto analysis of defects there are seven criteria that major problem that the company derived 80 % loss, whereas the cause-effect diagram analysis on the resulting fabric looms seen many become disabled, especially on the engine loom. Then remedial measures using the FMEA method, the results appear by RPN (Risk Priority Number) = 245, which is the largest value that takes priority action on equipment . The conclusion from these studies is the process of map control is done, there are 15 data are still outside of the control limit calculations, which is caused the data outside the control limits, that is caused by a specific causes within the system that is still not good. recommendations that can be given to the PT. PRIMISSIMA based on this analysis is to give priority to maintenance on the engine, especially on the components that are often damaged. It is expected that the improvement plan can be implemented and improve product quality in PT . PRIMISSIMA.

Kata Kunci : quality, DMAIC, DPMO, six sigma