DAFTAR ISI HALAMAN JUDUL ...................................................................................
i
SURAT PERNYATAAN .............................................................................
ii
LEMBAR PENGESAHAN PEMBIMBING ................................................
iii
LEMBAR PENGESAHAN PENGUJI .........................................................
iv
HALAMAN PERSEMBAHAN ...................................................................
v
MOTTO ........................................................................................................
vi
KATA PENGANTAR ….. ...........................................................................
vii
ABSTRAK….. .............................................................................................
ix
DAFTAR ISI ….. ..........................................................................................
x
DAFTAR TABEL .........................................................................................
xv
DAFTAR GAMBAR ...................................................................................
xvii
BAB I
BAB II
PENDAHULUAN 1.1 Latar Belakang ......................................................................
1
1.2 Rumusan Masalah .................................................................
3
1.3 Batasan Masalah ..................................................................
3
1.4 Tujuan Penelitian .................................................................
4
1.5 Manfaat Penelitian ..............................................................
4
1.6 Sistematika Penulisan ..........................................................
5
KAJIAN PUSTAKA 2.1 Konsep Lean .........................................................................
x
7
2.2 Konsep Lean Manufacturing ................................................
8
2.3.Pemborosan (waste) ..............................................................
10
2.4 Value Stream Mapping (VSM) ............................................
13
2.4.1 Langkah-langkah Value Stream Mapping ...................
14
2.4.2 Current State Value Stream Mapping ..........................
16
2.4.3 Simbol-simbol Value Stream Mapping ........................
18
2.5. Six Sigma .............................................................................
23
2.5.1 Konsep Six Sigma secara Statistik ...............................
25
2.5.2 Defini Kualitas .............................................................
26
2.5.3 Lean Six Sigma .............................................................
27
2.5.4 Metode DMAIC dalam Six Sigma ...............................
27
2.5.5 Pendekatan Lean Sigma ...............................................
34
2.5.6 Alat Pengendalian Kualitas Lean Sigma ......................
35
2.5.6.1 SIPOC (Supplier-Input-Process-Output-Cutomer
35
2.5.6.2 Diagram OPC (Operation Process Chart) .......
36
2.5.6.3 Diagram Pareto ................................................
38
2.5.6.4 Peta Kendali (Control Chart)...........................
38
2.5.6.5 Analisis Tingkat Sigma ....................................
40
2.5.6.6 Diagram Fishbone (Sebab-Akibat) ..................
40
2.5.6.7 Failure Mode and Effect Analysis (FMEA) .....
41
2.5.6.8 5W+1H .............................................................
42
2.5.6.9 Implementasi 5S...............................................
43
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BAB III
BAB IV
METODOLOGI PENELITIAN 3.1 Ruang Lingkup Penelitian.....................................................
44
3.2 Jenis dan Metode Pengumpulan Data ...................................
44
3.3 Pengolahan Data........................................................... ........
44
3.4 Analisis Data .........................................................................
48
3.5 Kesimpulan dan Saran ..........................................................
48
3.6 Diagram Alir Penelitian ........................................................
49
PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Gambaran Umum Perusahaan ...............................................
50
4.1.1 Sejarah Perusahaan ......................................................
50
4.1.2 Visi dan Misi Perusahaan .............................................
51
4.1.3 Struktur Organisasi ......................................................
51
4.2 Proses Produksi .....................................................................
51
4.3 Current State Value Stream Mapping ...................................
56
4.3.1 Menentukan Produk Yang Menjadi Model Line ..........
57
4.3.2 Menentukan Value Stream Manager ...........................
57
4.3.3 Aliran Informasi ...........................................................
57
4.3.4 Aliran Material .............................................................
58
4.3.5 Menetukan Takt Time ..................................................
59
4.3.6 Mengumpulkan Data Proses ........................................
59
4.3.7 Menghitung Inventory Process ....................................
62
4.3.8 Menghitung Process Cycle Time .................................
62
4.3.9 Menghitung Value Added Time ...................................
63
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.
BAB V
4.3.10 Menghitung Production Lead Time ...........................
63
4.3.11 Menghitung Process Cycle Efficiency .......................
63
4.4 Identifikasi Pemborosan (waste) ...........................................
65
4.5 Six Sigma ..............................................................................
66
4.5.1 Tahap Define (Pendefinisian) ......................................
66
4.5.1.1 Mendefinisikan proses kunci beserta pelanggan
66
4.5.2 Tahap Measure (Pengukuran) ......................................
68
4.5.2.1 Menentukan CTQ (Critical to Quality) ...........
68
4.5.2.2 Data Atribut .....................................................
71
4.5.3 Pengolahan Data ..........................................................
75
4.5.3.1 Menentukan Baseline Kinerja ..........................
86
4.5.4 Tahap Analyze (analisis) ..............................................
88
4.5.4.1 Mengidentifikasi Sumber-Sumber dan Akar ...
88
4.5.4.2 Mengidentifikasi Diagram Fishbone................
93
4.5.4.3 Failure Mode and Effect Analysis (FMEA) .....
95
PEMBAHASAN 5.1 Analisa Current State Mapping ............................................
103
5.2 Tahap Define (Pendefinisian)................................................
103
5.3 Tahap Measure (Pengukuran)…………………………….
104
5.3.1 Hasil Penentuan Critical to Quality (CTQ) .................
104
5.2.2 Hasil Pengukuran Baseline Kinerja .............................
104
5.4 Tahap Analyze (Analisis) ......................................................
105
5.4.1 Usulan Perbaikan Berdasarkan FMEA ........................
105
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BAB VI
5.5 Tahap Improve (Peningkatan). ..............................................
106
5.5.1 Pengembangan Rencana Tindakan dengan 5W+1H ....
107
5.5.2 Implementasi 5S...........................................................
108
5.6 Tahap Contol (Pengawasan) .................................................
110
KESIMPULAN DAN SARAN 6.1 Kesimpulan . ........................................................................
111
6.2 Saran . ..................................................................................
112
DAFTAR PUSTAKA LAMPIRAN
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DAFTAR TABEL Tabel 2.1 Simbol Proses Dalam Value Stream Mapping .......................................
19
Tabel 2.2 Simbol Material Dalam Value Stream Mapping ....................................
20
Tabel 2.3 Simbol Informasi Dalam Value Stream Mapping .................................
21
Tabel 2.4 Simbol Umum Dalam Value Stream Mapping ......................................
23
Tabel 2.5 hubungan spesifikasi, PPM dan kapabilitas proses ................................
26
Tabel 2.6 Manfaat Pencapaian Beberapa Tingkat Sigma (Boy Isma Putra,2010) .
35
Tabel 2.7 Simbol Diagram Proses (Sritomo,2003) ................................................
37
Tabel 4.1 Jenis – jenis produk yang menghasilkan kecacatan ...............................
68
Tabel 4.2 Jumlah cacat berdasarkan jenis cacat produk KS/SF..............................
69
Tabel 4.3 Hasil analisis data CTQ potensial jenis kegagalan .................................
70
Tabel 4.4 Karakteristik jenis cacat produk KS/SF ..................................................
71
Tabel 4.5 Data pengukuran jumlah cacat pada proses Finishing ............................
72
Tabel 4.6 Data pengukuran jumlah cacat pada proses sanding...............................
73
Tabel 4.7 Data pengukuran jumlah cacat pada proses assembly…………... .........
74
Tabel 4.8 Data pengukuran jumlah cacat pada proses sawmill ..............................
75
Tabel 4.9 Data untuk peta kendali bagian tak sesuai pada proses finishing ...........
76
Tabel 4.10 Data untuk peta kendali bagian tak sesuai pada proses sanding ...........
78
Tabel 4.11 Data untuk peta kendali bagian tak sesuai pada proses assembly ........
81
Tabel 4.12 Data untuk peta kendali bagian tak sesuai pada proses sawmill ...........
83
Tabel 4.13 Nilai DPMO dan tingkat sigma proses finishing ..................................
86
Tabel 4.14 Nilai DPMO dan tingkat sigma proses sanding ....................................
86
Tabel 4.15 Nilai DPMO dan tingkat sigma proses assembly .................................
87
Tabel 4.16 Nilai DPMO dan tingkat sigma proses milling .....................................
87
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Tabel 4.17 Data Jumlah Kegagalan .......................................................................
94
Tabel 4.18 Data Jumlah Kegagalan setelah dilakukan Detection ...........................
95
Tabel 4.19 Failure Mode and Effect Analysis (FMEA) .........................................
96
Tabel 4.20 Urutan Risk Priority Number (RPN) ....................................................
100
Tabel 5.1 Usulan Perbaikan Berdasarkan FMEA ................................................... 106
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DAFTAR GAMBAR
Gambar 2.1 Hubungan Kurva Normal dan Batas Sigma .............................
25
Gambar 2.2 Bentuk Diagram SIPOC ..........................................................
29
Gambar 2.3 Contoh diagram sebab-akibat (Larson, 2003) .........................
41
Gambar 3.1 Diagram Alir Penelitian ...........................................................
49
Gambar 4.1 Proses produksi PT. CHIA JIANN INDONESIA FURNITURE
54
Gambar 4.2 Current State Value Stream Mapping......................................
64
Gambar 4.3 Diagram SIPOC ........................................................................
66
Gambar 4.4 Operation Process Chart .........................................................
67
Gambar 4.5 Diagram pareto kecacatan produk………………………….
69
Gambar 4.6 Diagram pareto CTQ potensial jenis kegagalan........................
70
Gambar 4.7 Diagram fishbone penyebab amplasan mblaret/melintang .......
89
Gambar 4.8 Diagram fishbone penyebab warna botak (tidak berwarna) ......
90
Gambar 4.9 Diagram fishbone penyebab barang tergores & dekok .............
91
Gambar 4.10 Diagram fishbone penyebab belah log tebal tipis ...................
92
Gambar 4.11 HOUSE OF QUALITY (HOQ) ................................................
94
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