Publication Search

Ketidaksesuaian kualitas pada proses assembly sepatu kulit kerap memicu siklus rework berulang yang menguras sumber daya waktu maupun biaya produksi secara signifikan. Penelitian ini mengkaji mekanisme pengendalian cacat yang diterapkan pada Product D-01 di Lini C PT XYZ, dengan menggunakan DMAIC sebagai kerangka perbaikan utama serta Pareto, P-Chart, Fishbone Diagram, 5 Whys, Failure Mode and Effects Analysis (FMEA), dan Cost of Quality (COQ) sebagai alat pendukung. Data primer bersumber dari catatan produksi internal perusahaan, pengamatan lapangan, dan wawancara terstruktur bersama pengawas produksi dan staf quality control. Pengukuran baseline menunjukkan bahwa Lini C menyumbang volume cacat paling tinggi di antara seluruh lini yang ada, dengan Product D-01 mencatat 10.487 pair cacat dari total output 80.387 pair, sehingga menghasilkan defect rate sebesar 13,05%. Distribusi Pareto mengidentifikasi wrinkle, incorrect colour, dan not straight sebagai tiga kategori cacat paling kritis. Penilaian FMEA menetapkan Risk Priority Number tertinggi sebesar 245 pada perilaku operator yang terburu-buru selama proses lasting dan brushing. Tindakan korektif mencakup pemasangan SOP visual, implementasi checklist QC pra-shift, verifikasi kondisi mesin secara rutin, dan penyediaan sampel referensi warna serta bentuk yang terstandar. Pemantauan selama dua periode berikutnya mengkonfirmasi penurunan defect rate secara bertahap menjadi 12,80% dan kemudian 11,65%, disertai penurunan estimasi biaya kegagalan internal dari Rp 2,36 juta menjadi Rp 1,86 juta per periode.

This study aims to analyze the quality of granulated sugar products at PT Madukismo Yogyakarta using the Six Sigma methodology through the DMAIC approach (Define, Measure, Analyze, Improve, and Control). The main problems identified involve high variations in product quality and significant defects, particularly related to moisture content (less dry) and off-color products. Production and defect data from May 2023 to September 2024 were used to calculate DPMO and sigma levels as indicators of process performance. The results show that the sigma level ranges from 4.48 to 5.03, with the highest DPMO recorded at 1,456.76 and the lowest at 205.55, indicating that the process has not yet achieved Six Sigma performance. Pareto analysis reveals that color defects (58.4%) contribute the most to overall defects. The Fishbone diagram analysis indicates that defect causes originate from factors related to manpower, method, material, machine, measurement, and environment. Improvement recommendations include digitalizing monitoring systems, enhancing SOPs, upgrading operator competencies, modernizing machinery, improving raw material management, and strengthening environmental control systems. These improvements are expected to reduce DPMO to below 500 and increase the sigma level to at least 5.2. This study concludes that the Six Sigma approach is effective in identifying quality issues and formulating strategies to improve the quality of granulated sugar products at PT Madukismo.