UNIVERSITAS BINA NUSANTARA
Program Studi Ganda Teknik Industri – Sistem Informasi Skripsi Sarjana Program Ganda Semester Ganjil 2006/2007 Herdyan Widarmanto 0600664894 ABSTRAK
Sebagai penyedia komponen-komponen elektronik untuk perusahaan besar maka mutu dari produk yang dihasilkan PT. Pro Tec Indonesia harus dijaga dengan ketat. Munculnya cacat atau variasi dalam produk yang dihasilkan menjadi masalah yang penting dan membutuhkan penyelesaian yang baik. Adapun metode yang dipilih untuk melakukan perbaikan terhadap proses pengendalian mutu dan melakukan pencegahan terhadap terjadinya cacat pada produk adalah dengan menggunakan metode: (1) Statistical Process Control (SPC), untuk menghitung kapabilitas proses dari proses produksi, dan (2) Failure Mode and Effect Analysis, yang digunakan untuk menganalisa modus kegagalan dan akibat dari kegagalan tersebut agar dapat dilakukan perbaikan proses produksi apabila nilai kapabilitas proses berada dibawah nilai standar. Sistem pengendalian mutu saat ini yang diterapkan pada perusahaan adalah dengan menggunakan metode Statistical Process Control. Penulis mengusulkan penggunaan metode Failure Mode and Effect Analysis (FMEA) untuk menganalisa permasalahan kapabilitas proses produksi pada perusahaan. FMEA dapat mempermudah tim Quality Control dalam mencari solusi dari permasalahan yang ada. Dalam upaya mempermudah tim Quality Control melakukan pembuatan laporan permasalahan dan perancangan laporan FMEA, maka dirancang sebuah aplikasi FMEA.
Kata Kunci: Pengendalian mutu, Statistical Process Control, Failure Mode and Effect Analysis, sistem informasi,
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KATA PENGANTAR Sebelumnya penulis mengucapkan syukur dan terima kasih kepada Allah S.W.T. karena hanya atas izinNya penulis dapat menyelesaikan Skripsi ini. Walaupun tugas membuat Skripsi ini terasa berat oleh penulis, namun berkat bimbingan dari para dosen, akhirnya Skripsi ini dapat diselesaikan walaupun masih jauh dari kesempurnaan. Selama dilakukannya penyusunan Skripsi ini, penulis mendapatkan banyak dukungan, bantuan, bimbingan, dan masukkan dari berbagai pihak. Oleh karena itu, dalam kesempatan ini penulis ingin menyampaikan ucapan terima kasih kepada semua pihak yang telah banyak membantu dalam penyusunan Skripsi ini, khususnya kepada: 1. 2. 3. 4. 5. 6. 7.
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Bapak Prof. Dr. Gerardus Polla, M.App.Sc., selaku Rektor Universitas Bina Nusantara. Bapak Bahtiar Saleh Abbas, Ph.D., selaku Wakil Rektor 1. Bapak Ir. Sablin Yusuf, M.Sc,M.Comp.Sc, selaku Dekan Fakultas Ilmu Komputer. Bapak Iman H. Kartowisastro, Ph.D., selaku Dekan Fakultas Teknik. Bapak Ir. Gunawarman Hartono, M.Eng., selaku Ketua Jurusan Teknik Industri. Bapak Siswono, S.Kom, MM., selaku Ketua Jurusan Sistem Informasi. Bapak Ir. Landjono J, MSc., IE., IPM., selaku Dosen Pembimbing yang telah bersedia meluangkan waktu, tenaga, dan pikiran dalam membimbing penulis saat penyusunan Skripsi. Bapak Ir. Imam Djajono, MM., selaku Dosen Pembimbing yang telah bersedia meluangkan waktu, tenaga, dan pikiran dalam membimbing penulis saat penyusunan Skripsi. Bapak Sonny Maulana, Supervisor Quality Control PT Pro Tec Indonesia, yang telah bersedia meluangkan waktu memberikan bimbingan dan kesempatan kepada penulis untuk melaksanakan Skripsi ini. Seluruh staff Quality Control PT Pro Tec Indonesia, yang telah bersedia meluangkan waktu memberikan bimbingan dan arahan kepada penulis dalam pelaksanaan Skripsi. Orang tua dan keluarga yang telah memberikan dukungan, doa, dan semangat untuk menyelesaikan Skripsi ini. Anggra, Vero, NYP, Arindra, Christo dan teman-teman lainnya yang namanya tidak dapat disebut satu persatu yang telah membantu atau tidak membantu dan memberikan semangat kepada penulis dalam penyusunan Skripsi ini. B-Voice Radio, radio kampus Universitas Bina Nusantara yang telah menjadi tempat ketiga setelah rumah, dan perpustakaan tempat penulis melakukan penyusunan Skripsi. Crew B-Voice Radio, Tommy, Abu, Daviet, Danu, dan teman-teman lainnya yang namanya tidak dapat disebut satu persatu yang terus memberikan semangat kepada penulis untuk menyelesaikan Skripsi ini. vi
Penulis menyadari masih banyak kekurangan–kekurangan di dalam Skripsi, sehingga penulis sangat mengharapkan bantuan berupa kritik dari para dosen serta caracara yang baik untuk menyusun karya ilmiah di masa yang akan datang. Akhir kata, penulis berharap agar Skripsi ini dapat bermanfaat dan memberikan masukkan yang berguna bagi para pembaca sekalian.
Jakarta, 29 Juli 2007 Penulis
Herdyan Widarmanto 0600664894
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DAFTAR ISI
ABSTRAK ...................................................................................................................... iv PRAKATA....................................................................................................................... v DAFTAR TABEL .......................................................................................................... xi DAFTAR GAMBAR..................................................................................................... xii DAFTAR LAMPIRAN ................................................................................................. xv BAB I PENDAHULUAN............................................................................................... 1 1.1 Latar Belakang.....................................................................................................1 1.2 Identifikasi dan Perumusan Masalah ................................................................2 1.3 Ruang Lingkup.....................................................................................................3 1.4 Tujuan dan Manfaat............................................................................................4 1.4.1 Tujuan.............................................................................................................4 1.4.2 Manfaat ...........................................................................................................5 BAB 2 GAMBARAN UMUM PERUSAHAAN .......................................................... 6 2.1 Latar Belakang Perusahaan................................................................................6 2.2 Visi & Misi Perusahaan.......................................................................................9 2.2.1 Visi...................................................................................................................9 2.2.2 Misi ..................................................................................................................9 2.3 Struktur Organisasi ...........................................................................................10 2.4 Waktu Kerja Karyawan....................................................................................11 2.5 Production ...........................................................................................................11 2.5.1 Data Produksi...............................................................................................12 2.5.2 Proses Produksi ............................................................................................13 2.6 Quality Control....................................................................................................15 2.6.1 Incoming Quality Control.............................................................................16 2.6.2 Line Quality Control .....................................................................................16 2.6.3 Outgoing Quality Control .............................................................................19 2.7 Quality Policy ......................................................................................................19 BAB 3 LANDASAN TEORI ....................................................................................... 20 3.1 Metode Pengendalian Mutu ..............................................................................20 3.1.1 Definisi Mutu................................................................................................20 3.1.2 Pengendalian Mutu......................................................................................21 3.1.3 Jenis-Jenis Alat Bantu .................................................................................22 3.1.3.1 Diagram Pareto....................................................................................23 3.1.3.2 Diagram Sebab-Akibat .......................................................................24 3.2 Statistical Process Control ..................................................................................26 3.2.1 Tujuan Statistical Process Control ..............................................................27 3.2.2 Peta Kendali (Control Chart).......................................................................28 3.2.3 Jenis Peta Kendali........................................................................................29
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3.2.4 Prosedur Pembuatan Peta Kendali x dan R ............................................30 3.2.5 Prosedur Pembuatan Peta Kendali P.........................................................33 3.2.6 Interpretasi Peta Kendali ............................................................................34 3.3 Failure Mode and Effects Analysis (FMEA).....................................................37 3.3.1 Jenis-Jenis FMEA ........................................................................................37 3.3.2 Tahapan dalam FMEA................................................................................39 3.4 Sistem Informasi ................................................................................................43 3.4.1 Pengertian Sistem.........................................................................................43 3.4.2 Pengertian Informasi ...................................................................................43 3.4.3 Pengertian Sistem Informasi.......................................................................44 3.4.4 Analisa Sistem ..............................................................................................45 3.4.5 Perancangan Sistem.....................................................................................45 3.4.6 Pengertian Analisis Desain Berorientasi Objek (OOA&D)......................45 BAB 4 METODOLOGI PENELITIAN..................................................................... 50 4.1 Model Perumusan Masalah dan Pengambilan Keputusan ............................52 4.1.1 Studi Lapangan (Observasi) .......................................................................52 4.1.2 Identifikasi dan Perumusan Masalah ........................................................52 4.1.3 Studi Pustaka (Theoritical Framework) .....................................................52 4.1.4 Pembuatan Statistical Proces Control .........................................................52 4.1.5 Pembuatan Failure Mode and Effect Analysis ...........................................53 4.1.6 Perancangan dan Pembuatan Aplikasi ......................................................54 4.2 Teknik Pengumpulan Data dan Penentuan Parameter .................................55 BAB 5 HASIL DAN PEMBAHASAN........................................................................ 56 5.1 Analisa Teknik Industri ....................................................................................56 5.1.1 Pengumpulan data .......................................................................................56 5.1.1.1 Pengambilan Sampel ..........................................................................56 5.1.1.2 Acceptance Criteria..............................................................................57 5.1.1.3 Data Produksi......................................................................................59 5.1.2 Statistical Process Control (SPC).................................................................60 5.1.2.1 Pembuatan Histogram ........................................................................60 5.1.2.2 Perhitungan Data Variabel ................................................................65 5.1.2.3 Analisa Peta Kendali x dan R ...........................................................67 5.1.2.4 Perhitungan Capability Process Peta Kendali x dan R ...................70 5.1.2.5 Pembuatan Histogram........................................................................72 5.1.2.6 Perhitungan Data Atribut ..................................................................75 5.1.2.7 Analisa Peta Kendali p........................................................................78 5.1.2.8 Perhitungan Capability Process p-Chart............................................79 5.1.3 Failure Mode and Effect Analysis (FMEA) ................................................80 5.1.3.1 Identifikasi Potensi Failure Mode......................................................80 5.1.3.2 Identifikasi Potensi Akibat dari Failure Mode.................................87 5.1.3.3 Identifikasi Potensi Penyebab Failure Mode ....................................88 5.1.3.4 Evaluasi Current Controls...................................................................89 5.1.3.5 Penentuan Risk Priority Number........................................................91 5.1.3.6 Identifikasi Tindakan untuk Perbaikan ...........................................92
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5.1.3.7 Pembuatan Diagram FMEA ..............................................................92 5.1.3.8 Analisa FMEA.....................................................................................97 5.2 Pengembangan Sistem Informasi .....................................................................98 5.2.1 Definisi Sistem ..............................................................................................98 5.2.2 Functionality, Application Domain, Condition, Technology, Object, Repsonsibility Kriteria ..............................................................................101 5.2.3 Problem Domain Analysis ..........................................................................101 5.2.3.1 Class Diagram ....................................................................................102 5.2.3.2 Behavioral Pattern .............................................................................105 5.2.3.3 Event Table.........................................................................................108 5.2.4 Application Domain Analysis .....................................................................108 5.2.4.1 Use Case Diagram..............................................................................108 5.2.4.1.1 Actor Specification .....................................................................110 5.2.4.1.2 Use Case Specification...............................................................111 5.2.4.1.3 Spesifikasi dari Fungsi..............................................................115 5.2.4.2 Navigation Diagram...........................................................................116 5.2.4.3 User Interface.....................................................................................117 5.2.4.4 Sequence Diagram .............................................................................122 5.2.5 Component Design Analysis.......................................................................127 5.2.6 Architectural Design Analysis ....................................................................128 5.2.6.1 Component Diagram..........................................................................128 5.2.6.2 Deployment Diagram .........................................................................129 5.2.6.3 Spesifikasi Teknis..............................................................................130 5.2.6.4 Kriteria Aplikasi ...............................................................................131 BAB 6 SIMPULAN DAN SARAN............................................................................ 134 6.1 Simpulan ...........................................................................................................134 6.2 Saran .................................................................................................................135 DAFTAR PUSTAKA RIWAYAT HIDUP LAMPIRAN FOTOKOPI SURAT SURVEI
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DAFTAR TABEL
Tabel 2.1 PT Pro Tec Indonesia Main Customers Tabel 2.2 Informasi PT Pro Tec Indonesia ..........................................................................................................7 Tabel 2.2 Informasi PT Pro Tec Indonesia ......................................................................7 Tabel 2.3 Tonggak Bersejarah PT Pro Tec Indonesia .....................................................8 Tabel 3.1 Contoh Severity Rating ..................................................................................40 Tabel 3.2 Contoh Occurence Rating ..............................................................................40 Tabel 3.3 Contoh Detection Rating................................................................................41 Tabel 3.4 Contoh FMEA Worksheet ..............................................................................42 Tabel 5.1 Pengelompokan Data Variabel ......................................................................62 Tabel 5.2 Contoh Perhitungan Data Variabel Bushing 7x3 ...........................................65 Tabel 5.3 Pengelompokan Data Variabel ......................................................................73 Tabel 5.4 Perhitungan Data Atribut 7x3 ........................................................................76 Tabel 5.5 Jenis dan Jumlah Cacat Data Atribut Bushing 7x3 ........................................81 Tabel 5.6 Penilaian Occurrence Penyebab Failure Mode Hole Not Centered ..............88 Tabel 5.7 Penilaian Occurrence Penyebab Failure Mode Burry ...................................89 Tabel 5.8 Penilaian Detection untuk Metode Evaluasi berdasarkan sebab-sebab failure mode hole not centered ..................................................................................90 Tabel 5.9 Penilaian Detection untuk Metode Evaluasi berdasarkan sebab-sebab failure mode burry .....................................................................................................91 Tabel 5.10 Tabel FMEA Proses Pencetakan Bushing 7x3 ...............................................93 Tabel 5.11 Keterangan Grafik RPN untuk Failure Mode Hole Not Centered ................95 Tabel 5.12 Keterangan Grafik RPN untuk Failure Mode Burry .....................................96 Tabel 5.13 FACTOR Criteria ........................................................................................101 Tabel 5.14 Event Table ..................................................................................................108 Tabel 5.15 Function List ................................................................................................113 Tabel 5.16 Windows & Print-Outs.................................................................................118 Tabel 5.17 Pola Arsitektur Client-Server.......................................................................128 Tabel 5.18 Kriteria untuk Kualitas Software .................................................................132
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DAFTAR GAMBAR
Gambar 2.1 Struktur Organisasi PT Pro Tec Indonesia...................................................10 Gambar 2.2 Diagram Pareto Part PT Pro Tec Indonesia .................................................12 Gambar 2.3 Mesin Feeder Metal Coil..............................................................................13 Gambar 2.4 Metal Coil sedang ditarik .............................................................................14 Gambar 2.5 Mesin Press CS ............................................................................................14 Gambar 2.6 Jig atau Dies .................................................................................................15 Gambar 2.7 Digital Caliper .............................................................................................18 Gambar 2.8 Projector ......................................................................................................18 Gambar 3.1 Contoh Pareto Diagram................................................................................24 Gambar 3.2 Contoh Fishbone Diagram...........................................................................26 Gambar 3.3 Model Deteksi ..............................................................................................27 Gambar 3.4 Model Pencegahan .......................................................................................27 Gambar 3.5 Tahapan FMEA............................................................................................39 Gambar 4.1 Model Metodologi Penelitian (bagian 1) .....................................................50 Gambar 4.2 Model Metodologi Penelitian (bagian 2) .....................................................51 Gambar 5.1 Check Point untuk Bushing 7x3 ...................................................................57 Gambar 5.2 Spesifikasi Check Point untuk Bushing 7x3 ................................................58 Gambar 5.3 Tally Histogram untuk Data Variabel Bushing 7x3 .....................................63 Gambar 5.4 Histogram untuk Data Variabel Bushing 7x3 ..............................................64 Gambar 5.5 Peta Kendali x dan R untuk Bushing 7x3 .....................................................67 Gambar 5.6 Peta Kendali x dan R (Revisi) untuk Bushing 7x3 ........................................69 Gambar 5.7 Tally Histogram untuk Data Atribut Bushing 7x3 .......................................74 Gambar 5.8 Histogram untuk Data Atribut Bushing 7x3 ................................................74 Gambar 5.9 Peta Kendali p untuk Bushing 7x3 ...............................................................77 Gambar 5.10 Diagram Pareto Failure Mode Bushing 7x3 ..............................................82 Gambar 5.11 Diagram Sebab-Akibat untuk Cacat Hole Not Centered ...........................83 Gambar 5.12 Diagram Sebab-Akibat untuk Cacat Burry ................................................85 Gambar 5.13 Grafik RPN untuk Failure Mode Hole Not Centered ................................95 Gambar 5.14 Grafik RPN untuk Failure Mode Burry .....................................................96 Gambar 5.15 Rich Picture Production and Outgoing Quality Process ...........................99 Gambar 5.16 Class Diagram .........................................................................................102 Gambar 5.17 Statechart Diagram Line Quality Control ...............................................106 Gambar 5.18 Statechart Diagram Production ...............................................................106 Gambar 5.19 Statechart Diagram Ms_Part ...................................................................106 Gambar 5.20 Statechart Diagram Form_ITR ................................................................107 Gambar 5.21 Statechart Diagram Form_FMEA ...........................................................107 Gambar 5.22 Use Case Diagram ...................................................................................109 Gambar 5.23 Navigation Diagram ................................................................................116 Gambar 5.24 Window Login ..........................................................................................118 Gambar 5.25 Window Master Part ................................................................................119 Gambar 5.26 Window Internal Trouble Report .............................................................119 Gambar 5.27 Window Controls for Conformities (Solution) .........................................120
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Gambar 5.28 Failure Mode and Effect Analysis ............................................................121 Gambar 5.29 Sequence Diagram Login .........................................................................122 Gambar 5.30 Sequence Diagram Entry Ms_Part ..........................................................123 Gambar 5.31 Sequence Diagram Form ITR .................................................................124 Gambar 5.32 Sequence Diagram Form Update ITR......................................................125 Gambar 5.33 Sequence Diagram Form FMEA..............................................................126 Gambar 5.34 Revised Class Diagram ............................................................................127 Gambar 5.35 Component Diagram ................................................................................128 Gambar 5.36 Deployment Diagram ...............................................................................129
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DAFTAR LAMPIRAN LI Lampiran 1 ........................................................................................................... L1 Tabel Pengumpulan Data Atribut Bushing 7x3 Bulan Nopember s/d Desember 2006..................................................................................................................... L1 Tabel Pengumpulan Data Variabel Check Point 2 Bushing 7x3............................ L2 LII Lampiran 2 ........................................................................................................... L3 Tabel Perhitungan Diagram Pareto Part PT Pro Tec Indonesia Bulan September 2006..................................................................................................................... L3 Tabel Perhitungan Data Variabel Bushing 7x3 ...................................................... L4 Tabel Perhitungan Data Atribut Bushing 7x3 ........................................................ L5 Tabel Perhitungan Data Variabel Revisi Bushing 7x3 ........................................... L6 Tabel Perhitungan Diagram Pareto untuk Jenis Cacat Visual Bushing 7x3 Bulan Nopember s/d Desember................................................................................... L7 LIII Lampiran 3 ........................................................................................................... L8 Tabel Konstanta untuk Peta Kendali x dan R Chart............................................. L8 Tabel Area dibawah Kurva Normal ........................................................................ L9 G Chart untuk Menentukan Jumlah Kelompok Data .......................................... L10
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