Usulan penerapan metode lean six sigma pada proses produksi frame panel listrik di PT. Himalaya Transmeka

DETAIL KOLEKSI

Usulan penerapan metode lean six sigma pada proses produksi frame panel listrik di PT. Himalaya Transmeka

Oleh : Stephanie Mulyadi

Info Katalog

Penerbit : FTI - Usakti

Kota Terbit : Jakarta

Tahun Terbit : 2008

Pembimbing 1 : Dedy Sugiarto

Pembimbing 2 : Rahmi Maulidya

Subyek : Quality control;Electric power transmission;Six sigma - quality control standard;Production control;Quality control

Kata Kunci : PT. Himalaya Transmeka, quality control, electric power transmission, six sigma, quality control sta

Status Posting : Published

Status : Tidak Lengkap

File Repositori

No.	Nama File	Hal.	Link
1.	2008_TA_STI_06304015_Halaman-Judul.pdf
2.	2008_TA_STI_06304015_Lembar-Pengesahan.pdf
3.	2008_TA_STI_06304015_Bab-1_Pendahuluan.pdf
4.	2008_TA_STI_06304015_Bab-2_Tinjauan-Pustaka.pdf
5.	2008_TA_STI_06304015_Bab-3_Metodologi-Penelitian.pdf
6.	2008_TA_STI_06304015_Bab-4_Pengumpulan-Data.pdf
7.	2008_TA_STI_06304015_Bab-5_Pengolahan-Data.pdf
8.	2008_TA_STI_06304015_Bab-6_Kesimpulan-dan-Saran.pdf
9.	2008_TA_STI_06304015_Daftar-Pustaka.pdf
10.	2008_TA_STI_06304015_Lampiran.pdf

Abstrak
Abstract

P ersaingan industri yang semakin berkembang mendorong PT. Himalaya Transmeka sebagai produsen panel listrik selalu berupaya untuk meningkatkan kualitas serta kecepatan produksinya. Dalam penelitian ini, produk yang diamati adalahframe panel listrik sebagai salah satu penyusun panel listrik. Berdasarkan hasil pengamatan, diketahui bahwa proses pengecatan pada prose s produksi frame panel listrik memiliki persentase cacat paling besar, yaitu 9,928%. Persentase cacat yang besar dapat mengurangi kualitas serta efisiensi waktu produksi karena sebagian besar produk cacat akan melewati rework untuk perbaikan. Penelitian yang dilakukan bertujuan untuk mengidentifikasi jenis cacat yang paling dominan beserta penyebabnya pada proses pengecatan frame panel listrik, menghitung kapabilitas proses, tingkat sigma, efisiensi siklus proses dan kecepatan proses , serta memberikan usulan perbaikan terhadap kualitas dan efisiensi waktu produksi frame panellistrik.Metode Lean Six Sigma digunakan dalam upaya peningkatan kualitas dan kecepatanproses produksi dalam penelitian ini. Berdasarkan diagram alir proses produksiframe panel listrik serta value stream perusahan, maka dilakukan pengukuran waktu siklus proses yang pada akhimya diperoleh total lead time serta value-added time. Hasil perhitungan menunjukkan efisiensi siklus proses sebesar 51,72% dan kecepatan proses sebesar 44,88 aktivitas/jam (untuk 4 unit frame panel listrik). Pemetaan time traps menunjukkan proses pengecatan memiliki persentase waktu rework paling besar, yaitu sebesar 3,68%. Persentase waktu menunggu terbesar terdapat pada proses menunggu untuk frame assembling, yaitu sebesar 13,71%.Karakteristik kualitas yang penting bagi konsumen (Critical to Quality/CTQ) danpotensial menimbulkan cacat pada proses pengecatan yaitu kasar, tergores, belong, meleber, ketidaksesuaian wama (karakteristik atribut produk), serta ketidaksesuaian ketebalan cat (karakteristik variabel produk). Perhitungan data atribut produk menunjukkan DPMO (Defect Per Million Opportunities) sebesar 29035,8744 dengan tingkat sigma 3,4. Perhitungan data variabel produk menunjukkan kapabilitas proses (Cpk) sebesar 0,54, ppm sebesar 52600. Berdasarkan diagram pareto dari jenis cacat atribut, diketahui bahwa kasar, tergores, dan bolong merupakan cacat yang paling dominan, serta ketidaksesuaian ketebalan cat dari cacat variabel.Hasil analisa yang dilakukan menggunakan peta aliran proses, diagram sebab akibat, dan analisa 5 Whys menunjukkan bahwa area pengecatan yang belum tertata rapi, metode perpindahan material yang kurang tepat, serta kurangnya pelatihan operator memberikan pengaruh yang cukup besar pada terjadinya rework sebagian besar material. Hal ini membuat kualitas produksiframe panellistrik pada proses pengecatan menurun dan berpengaruh pada kecepatan proses. Usulan perbaikan menggunakan metode 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) pada bagian pengecatan dapat menciptakan dan memelihara agar tempat kerja menjadi teratur, bersih, aman, dan memiliki kinerja tinggi. Pengadaan program pelatihan dapat meningkatkan keterampilan operator serta perbaikan metode perpindahan dapat meminimasi waktu siklus proses. Usulan perbaikan yang ada diharapkan dapat meningkatkan efisiensi siklus proses dan tingkat sigma perusahaan.

T he growing industry competition pushed PT. Himalaya Transmeka as an electrical panel manufacturer always strives to improve the quality and speed of its production. In this study, the product observed was the electrical panel frame as one of the constituents of the electrical panel. Based on observations, it is known that the painting process in the production process of electric panel frames has the greatest percentage of defects, which is 9.928%. A large percentage of defects can reduce the quality and efficiency of production time because most defective products will go through rework for repairs. The research conducted aims to identify the most dominant types of defects and their causes in the process of painting electric panel frames, calculate process capability, sigma level, process cycle efficiency and process speed, and provide suggestions for improvements to the quality and efficiency of panellistric frame production time. Lean Six method Sigma is used in an effort to improve the quality and speed of production processes in this study. Based on the electrical panel production process flow chart and the company's value stream, the process cycle time is measured, which ultimately results in total lead time and value-added time. The calculation results show the efficiency of the process cycle of 51.72% and the speed of the process of 44.88 activities / hour (for 4 units of electric panel frames). Time traps mapping shows that the painting process has the largest percentage of rework time, which is 3.68%. The largest percentage of waiting time is found in the process of waiting for frame assembling, which is 13.71%. Critical to Quality (CTQ) characteristics and the potential to cause defects in the painting process are rough, scratched, belonged, meleber, color mismatch (color) product attribute characteristics), and paint thickness mismatch (product variable characteristics). Calculation of product attribute data shows DPMO (Defect Per Million Opportunities) of 29035,8744 with a sigma level of 3,4. Calculation of product variable data shows the process capability (Cpk) of 0.54, ppm of 52600. Based on the Pareto diagram of the type of attribute defects, it is known that rough, scratched, and perforated are the most dominant defects, as well as mismatch paint thickness from variable defects. analysis carried out using process flow maps, cause and effect diagrams, and analysis 5 Whys shows that the painting area is not yet neatly arranged, the method of material displacement is less precise, and the lack of operator training gives a considerable influence on the rework of most materials. This makes the quality of the panellelectric frame production in the painting process decrease and affect the speed of the process. The proposed improvement using the 5S method (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) in the painting section can create and maintain so that the workplace is organized, clean, safe, and has high performance. Providing training programs can improve operator skills and improve transfer methods to minimize process cycle time. The proposed improvement is expected to improve the efficiency of the process cycle and the level of company sigma.