DAFTAR ISI. HALAMAN PENGAKUAN... ii. SURAT PENGAMBILAN DATA DARI PERUSAHAAN... iii. HALAMAN PENGESAHAN PEMBIMBING... iv. HALAMAN PERSEMBAHAN

DAFTAR ISI

HALAMAN JUDUL ................................................................................................ i HALAMAN PENGAKUAN .................................................................................... ii SURAT PENGAMBILAN DATA DARI PERUSAHAAN .................................... iii HALAMAN PENGESAHAN PEMBIMBING ........................................................ iv HALAMAN PENGESAHAN PENGUJI ................................................................. v HALAMAN PERSEMBAHAN ............................................................................... vi HALAMAN MOTTO ............................................................................................... vii KATA PENGANTAR .............................................................................................. viii ABSTRAK ................................................................................................................ x TAKARIR ................................................................................................................. xi DAFTAR SIMBOL .................................................................................................. xiii DAFTAR ISI ............................................................................................................. xiv DAFTAR TABEL ..................................................................................................... xix DAFTAR GAMBAR ................................................................................................ xx

BAB I PENDAHULUAN ........................................................................................ 1 1.1

Latar Belakang ..................................................................................... 1

1.2

Rumusan Masalah ................................................................................ 3

1.3

Batasan Masalah .................................................................................. 4

1.4

Tujuan Penelitian ................................................................................. 4

1.5

Manfaat Penelitian ............................................................................... 5

1.6

Sistematika Penulisan .......................................................................... 5

BAB II KAJIAN LITERATUR ............................................................................ 7 xiv

2.1 Kajian Pustaka Terdahulu .................................................................. 7 2.2 Konsep Kualitas ................................................................................. 9 2.2.1

Definisi Kualitas ................................................................... 9

2.2.2

Pengendalian Kualitas (Quality Control) ............................. 10

2.2.3

Perbaikan Kualitas (Quality Improvement) .......................... 11

2.3 Six Sigma ............................................................................................ 11 2.3.1

Latar Belakang Six Sigma ..................................................... 11

2.3.2

Definisi Six Sigma ................................................................. 12

2.3.3

Metodologi Six Sigma ........................................................... 13

2.3.4

Istilah-Istilah Dalam Konsep Six Sigma ............................... 15

2.3.5

Tim Six Sigma ....................................................................... 20

2.3.6

Manfaat Six Sigma ................................................................. 23

2.4 Tools Six Sigma .................................................................................. 25 2.4.1

Diagram Pareto ..................................................................... 26

2.4.2

Analisis Gap .......................................................................... 26

2.4.3

Peta Kendali Proses .............................................................. 27

2.4.4

Kapabilitas Proses ................................................................. 32

2.4.5

Root Cause Analysis ............................................................. 34

2.5 Failure Mode And Effect Analysis (FMEA) ...................................... 37 2.5.1

Definisi FMEA ...................................................................... 37

2.5.2

Tujuan Dan Manfaat Penggunaan FMEA ............................. 38

2.5.3

Istilah-Istilah Dalam FMEA .................................................. 40

2.6 Formulir 5W-2H ................................................................................ 41

BAB III METODE PENELITIAN ........................................................................ 44 3.1 Identifikasi Awal Penelitian ............................................................... 44

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3.1.1

Latar Belakang Masalah ....................................................... 48

3.1.2

Rumusan Masalah ................................................................. 48

3.1.3

Tujuan Penelitian .................................................................. 48

3.1.4

Studi Pustaka ......................................................................... 49

3.2 Pengumpulan Dan Pengolahan Data .................................................. 49 3.2.1

Define .................................................................................... 50 3.2.1.1 Pemetaan Proses ...................................................... 50 3.2.1.2 Identifikasi Kebutuhan Pelanggan ........................... 50 3.2.1.3 Pembuatan Dan Penyebaran Kuisioner .................... 50 3.2.1.4 Uji Validitas Dan Realibilitas .................................. 51 3.2.1.5 Penentuan Critical To Quality Kunci ...................... 52

3.2.2

Measure ................................................................................ 53 3.2.2.1 Pengumpulan Data Critical To Quality Kunci ........ 53 3.2.2.2 Pengukuran Level Sigma ......................................... 53

3.2.3

Analyze .................................................................................. 54 3.2.3.1 Analisa Stabilitas Proses .......................................... 54 3.2.3.2 Analisa Kapabilitas Proses ....................................... 55 3.2.3.3 Analisa Sumber-Sumber Variasi Dan Akar Penyebab Masalah .................................................. 56 3.2.3.4 Membuat Failure Mode And Effect Analysis ........... 56

3.2.4

Improve Dan Control ............................................................ 59

3.3

Pembahasan ...................................................................................... 59

3.4

Kesimpulan Dan Saran ..................................................................... 59

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA ................................. 61 4.1

Tahap Define ..................................................................................... 61 4.1.1

Pembuatan Peta Aliran Proses .............................................. 61 xvi

4.2

4.1.2

Penentuan Karakteristik Kualitas .......................................... 64

4.1.3

Pembauatan Dan Penyebaran Kuisioner ............................... 65

4.1.4

Pengujian Validitas Dan Realibilitas .................................... 65

4.1.5

Penentuan Critical To Quality Kunci ................................... 65

Tahap Measure ................................................................................. 72 4.2.1

4.3

Pengukuran Kemampuan Proses .......................................... 74

Tahap Analyze ................................................................................... 75 4.3.1

Pengukuran Kestabilan Proses .............................................. 75

4.3.2

Pengukuran Kapabilitas Proses ............................................. 78

4.3.3

Analisa Sumber-Sumber Variasi Dan Akar Penyebab Masalah ................................................................................. 80

4.3.4

Membuat Failure Mode And Effect Analysis ........................ 89

4.4

Tahap Improve ..................................................................................109

4.5

Tahap Control ...................................................................................121

BAB V PEMBAHASAN .........................................................................................123 5.1

Tahap Define .....................................................................................123

5.2

Tahap Measure .................................................................................124

5.3

5.2.1

Analisis Level Sigma ............................................................124

5.2.2

Analisis Stabilitas Proses ......................................................125

5.2.3

Analsis Kapabilitas Proses ....................................................125

Tahap Analyze ...................................................................................126 5.3.1

Analisis Penelusuran Akar Penyebab Masalah .....................126

5.3.2

Analsis Pengaruh Potensial Kegagalan Sumber Variasi .......127

5.4

Tahap Improve ..................................................................................129

5.5

Tahap Control ...................................................................................131

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BAB VI PENUTUP ...............................................................................................133 6.1

Kesimpulan 133

6.2

Saran ...........................................................................................................13 5

DAFTAR PUSTAKA LAMPIRAN

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DAFTAR TABEL

Tabel 2.1

Kapabilitas Proses Sigma Terpusat Dan Pergeseran Proses..............33

Tabel 2.2

Contoh Formulir 5W-2H....................................................................42

Tabel 4.1

Jumlah Defect Berdasarkan ke-5 CTQ ..............................................66

Tabel 4.2

Customer Importance ........................................................................69

Tabel 4.3

Customer Satisfication.......................................................................70

Tabel 4.4

Selisih Customer Importance dan Customer Satisfication ................71

Tabel 4.5

Data Defact Produksi Kaos Bulan Oktober 2009 ..............................73

Tabel 4.6

Rekap Data CL, UCL, dan LCL Untuk Bulan Januari 2006 .............76

Tabel 4.7

Tabel Konversi Level Sigma..............................................................78

Tabel 4.8

Failure Mode and Failure Effect .......................................................90

Tabel 4.9

Skala Security ....................................................................................91

Tabel 4.10

Skala Severity Failure Effect dan Failure Mode................................91

Tabel 4.11

Causes Dari Failure Mode.................................................................94

Tabel 4.12

Skala Occurrence...............................................................................95

Tabel 4.13

Skala Occurrence dan Failure Mode.................................................96

Tabel 4.14

Kejadian Yang Mungkin Terjadi Karena Kegagalan dan Metode Pengendaliannya ................................................................................103

Tabel 4.15

Skala Detection ..................................................................................106

Tabel 4.16

Nilai Detection Control dan Failure Mode ........................................106

Tabel 4.17

Risk Priority Number .........................................................................109

Tabel 4.18

Perbaikan Kualitas Kaos ....................................................................110

Tabel 4.19

Standar Penerimaan Kualitas .............................................................116

DAFTAR GAMBAR xix

Gambar 2.1

Contoh Diagram Sebab Akibat ......................................................... 37

Gambar 3.1

Diagram Alir Penelitian .................................................................... 45

Gambar 4.1

Peta Aliran Proses ............................................................................. 62

Gambar 4.2

Diagram Pareto ................................................................................. 67

Gambar 4.3

Peta Kendali p ................................................................................... 77

Gambar 4.4

Cause Effect Diagram ....................................................................... 81

Gambar 4.5

Operation Process Chart Perusahaan ...............................................114

Gambar 4.6

Operation Process Chart Usulan ......................................................115

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DAFTAR SIMBOL

s

= Standar deviasi

r

= Angka korelasi

n

= Jumlah data

k

= Banyaknya butir pertanyaan

r11

= Reliabilitas alat ukur

σ2 t

= Variansi total

Σσ2b

= Jumlah variansi butir

p

= Nilai proporsi cacat

CL

= Garis tengah

LCL

= Batas kendali bawah

UCL

= Batas kendali atas

Cp

= Kapabilitas proses

Cpk

= Indeks kapabilitas proses

S

= Tingkat keseriusan masalah

O

= Frekuensi terjadinya masalah

D

= Metode pengendalian

Sp

= Nilai simpangan baku

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TAKARIR

Output

= Produk akhir yang dihasilkan

T-shirt

= Kaos

Quality assurance

= Jaminan kualitas

Problem solving tools

= Alat-alat untuk memecahkan masalah

Zero Defect

= Kegagalan nol

Measurement

= Pengukuran

Critical to quality

= Karakteristik kualitas

Defect per million opportunity

= Kegagalan per satu juta kesempatan

Special cause variation

= Variasi penyebab khusus

Common cause variation

= Variasi penyebab umum

Cost of poor quality

= Biaya-biaya ekstra karena output yang dihasilkan kurang memenuhi persyaratan

Supplier

= Pemasok bahan baku

Performance

= Performansi

Defect

= Cacat

Voice Of Customer

= Suara pelanggan

Maintenance

= Perawatan

Customer impotrtance

= Tingkat kepentingan pelangan

Customer satisfication

= Tingkat kepuasan pelanggan

Customer requirement

= Daftar kebutuhan pelanggan

Lower control limit

= Batas kendali bawah xi

Upper control limit

= Batas kendali atas

Root cause analysis

= Identifikasi akar penyebab masalah

Critical characteristic

= Karakterisitik kritis

Severity

= Tingkat keseriusan masalah

Occurance

= Frekuensi terjadinya masalah

Detection

= Metode pengendalian

Risk priority number

= Nilai yang menentukan prioritas perbaikan

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