DAFTAR ISI
HALAMAN JUDUL.................................................................................................i LEMBAR PENGESAHAN PEMBIMBING...........................................................ii LEMBAR PENGESAHAN PENGUJI................................................................iii HALAMAN PERSEMBAHAN...........................................................................iv HALAMAN MOTTO…..…………………………………………………………v KATA
PENGANTAR…………………………………………………………vi
DAFTAR ISI………………………………………………………...………..…viii DAFTAR TABEL………………………………………………………………xiv DAFTAR GAMBAR………………………………………………………...…..xv ABSTRAKSI.......................................................................................................xvii BAB I PENDAHULUAN 1.1 Latar Belakang Masalah……………………………………………….1 1.2 Rumusan Masalah…………………………………………...………...3 1.3 Batasan Masalah…………………………………………………….....3 1.4 Tujuan Penelitian………………………………………....…………....3 1.5 Manfaat Penelitian……………………………………………………..4 1.6 Sistematika Penulisan………………………………….………………4
BAB II LANDASAN TEORI 2.1 Pengertian Kualitas……………………………………………………8 2.1.1 Pengertian Tentang Pengendalian ………….……………...10
2.1.2 Pengendalian Kualitas...........................................................11 2.2 Pengertian Six Sigma …………..…………...………........................12 2.2.1 Metodologi Six Sigma...........................................................15 2.2.2 Tools Dalam Six Sigma……………………………………19 2.2.3 Analisis DPMO Dan Tingkat Sigma.....................................34 2.2.3.1 Analisis DPMO dan tingkat sigma untuk data atribut.....................................................................34 2.2.3.2 Analisis DPMO dan tingkat sigma untuk data variabel...................................................................35 2.2.4 Kapabilitas Proses………………………………………….35 2.3 Pengertian Lean………………………………………………………37 2.3.1 Pengertian Pemborosan (waste)............................................39 2.3.2 Identifikasi Pemborosan……………………………………39 2.4 Pengertian Lean Sigma.........................................................................43 2.4.1 Tindakan Untuk Melaksanakan Peningkatan Kualitas LeanSigma.............................................................................45
BAB III METODOLOGI PENELITIAN 3.1 Pendahuluan ........................................................................................46 3.2 Studi pustaka........................................................................................46 3.3 Pengumpulan Data...............................................................................48 3.4 Pengolahan Data...................................................................................49 3.5 Analisis Data........................................................................................52
3.6 Kesimpulan dan Saran..........................................................................52
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Pengumpulan Data...............................................................................53 4.1.1 Sejarah dan Perkembangan Perusahaan................................53 4.1.1.1
Sejarah
Singkat
Berdirinya
GE
Lighting
Indonesia.............................................................54 4.1.2 Visi dan Misi Perusahaan......................................................55 4.1.2.1 Visi PT GE Lighting Indonesia..............................55 4.1.2.2 Misi PT GE Lighting Indonesia.............................56 4.1.3 Tinjauan Produksi.................................................................56 4.1.3.1 Kapasitas dan Hasil Produksi.................................56 4.1.3.2 Bahan Baku………………………………………57 4.1.3.3 Proses Produksi……………………………………..........60 4.1.3.4 Quality Control…………………………………...63 4.1.3.5 Data Umum Perusahaan………………………….64 4.1.4 Tahap Define (pendefinisian)............................................................67 4.1.4.1 Mendefinisikan proses kunci beserta pelanggan....67 4.1.5 Tahap Measure (pengukuran)................................................69 4.1.5.1 Menentukan Critical to Quality (CTQ)..................69 4.1.5.2 Data Atribut............................................................74 4.1.5.3 Data Variabel..........................................................76 4.2 Pengolahan Data...................................................................................79
4.2.1 Uji Kecukupan Data dan Uji Statistical Process Control Data Atribut...................................................................................79 4.2.1.1 Proses Mounting.....................................................79 4.2.1.2 Proses Basing.........................................................82 4.2.2 Uji Kecukupan Data dan Uji Statistical Process Control Data Variabel.................................................................................85 4.2.2.1 Tebal Clamp...........................................................85 4.2.2.2 Tinggi Mounting....................................................89 4.2.3 Menentukan Baseline Kinerja (DPMO dan Tingkat Sigma) Data Atribut...........................................................................92 4.2.3.1 Proses Mounting.....................................................92 4.2.3.2 Proses Basing.........................................................93 4.2.4 Menentukan Baseline Kinerja (DPMO dan Tingkat Sigma) Data Variabel.........................................................................94 4.2.4.1 Tebal Clamp...........................................................94 4.2.4.2 Tinggi Mounting....................................................95 4.2.5 Tahap Analyze (Analisis)......................................................96 4.2.5.1 Menentukan Stabilitas Proses.................................96 4.2.5.1.1 Tebal Clamp............................................96 4.2.5.1.2 Tinggi Mounting.....................................98 4.2.5.2 Menentukan Kapabilitas Proses.............................99 4.2.5.2.1 Tebal Clamp............................................99 4.2.5.2.2 Tinggi Mounting...................................100
4.2.6 Mengidentifikasi Sumber-sumber dan Akar Penyebab Kecacatan............................................................................101 4.2.6.1 Diagram Sebab Akibat Untuk Tebal Clamp........101 4.2.6.2 Diagram Sebab Akibat Untuk Tinggi Mounting..104 4.2.6.3 Diagram Sebab Akibat Untuk Lubang Arbor Samping...................................................................107 4.2.6.4 Diagram Sebab Akibat Untuk Solder Samping/Las LIW Samping..........................................................110 4.2.7 Tahap Improve (peningkatan)............................................113 4.2.7.1
Mengidentifikasi
Nilai
Produk
Berdasarkan
Prespektif Pelanggan.........................................113 4.2.7.2 Mengidentifikasi Aliran Proses............................114 4.2.7.3 Menghilangkan Aktivitas Pemborosan Yang Tidak Bernilai Tambah................................................116 4.2.7.3.1 Mengidentifikasi Pemborosan (waste)..116 4.2.7.4 Analisa Penyebab Terjadinya Pemborosan..........117 4.2.8 Tahap Control (pengawasan)..............................................121
BAB V PEMBAHASAN 5.1 Tahap Define (pendefinisian).............................................................122 5.2 Tahap Measure (pengukuran).............................................................122 5.2.1 Penentuan Karakteristik Kualitas Kunci (CTQ)..................122 5.2.2 Hasil Tingkat Ketidaksesuaian dan Uji Kendali Produk.....123
5.2.3 Hasil Pengukuran Baseline Kinerja (DPMO dan tingkat Sigma) Data Atribut............................................................124 5.2.4 Hasil Pengukuran Baseline Kinerja (DPMO dan tingkat Sigma) Data Variabel..........................................................124 5.3 Tahap Analyze (analisis)....................................................................125 5.3.1 Analisa Stabilitas Proses.....................................................125 5.3.2 Analisa Kemampuan Proses................................................126 5.3.3 Identifikasi Sumber dan Akar Penyebab Kecacatan...........127 5.4 Tahap Improve (peningkatan)............................................................128 5.5 Tahap Control (pengawasan).............................................................130
BAB VI PENUTUP 6.1 Kesimpulan………………………………………………………….132 6.2 Saran………………………………………………………………...133
DAFTAR PUSTAKA LAMPIRAN
DAFTAR TABEL
Tabel 2.1 Perbedaan true 6-sigma dengan motorola 6-sigma................................14 Tabel 2.2 Simbol Diagram Proses..........................................................................21 Tabel 2.3 Contoh Tabel PICA................................................................................25 Tabel 2.4 “seven plus one” type of waste………………………………………..40 Tabel 2.5 Pendekatan untuk reduksi pemborosan..................................................42 Tabel 4.1 Jenis-jenis produk yang menghasilkan kecacatan..................................69 Table 4.2 Jumlah cacat berdasarkan jenis cacat produk GLS 60………………...71 Tabel 4.3 Hasil analisis data CTQ potensial jenis kegagalan……………………72 Tabel 4.4 Karakteristik jenis cacat produk GLS 60……………………………...73 Tabel 4.5 Data pengukuran jumlah cacat pada proses mounting………………...74 Tabel 4.6 Data pengukuran jumlah cacat pada proses basing……………………75 Tabel 4.7 Data pengukuran tebal clamp GLS 60………………………………...76 Tabel 4.8 Data pengukuran tinggi mounting GLS 60……………………………77 Tabel 4.9 Data untuk peta kendali bagian tak sesuai proses mounting…………..79 Tabel 4.10 Data untuk peta kendali bagian tak sesuai proses basing…………….82 Tabel 4.11 Hasil pengolahan data untuk tebal clamp…………………………….85 Tabel 4.12 Hasil pengolahan data untuk tinggi mounting……………………….89 Tabel 4.13 Nilai DPMO dan Tingkat Sigma Proses Mounting..............................92 Tabel 4.14 Nilai DPMO dan Tingkat Sigma Proses Basing..................................93
DAFTAR GAMBAR
Gambar 2.1 Konsep six sigma motorola dengan distribusi normal bergeser 1,5sigma.................................................................................................13 Gambar 2.2 Siklus metode Six Sigma DMAIC.....................................................18 Gambar 2.3 Contoh CTQ Tree...............................................................................19 Gambar 2.4 Diagram proses map..........................................................................21 Gambar 2.5 Contoh diagram tulang ikan...............................................................24 Gambar 2.6 Contoh control chart..........................................................................26 Gambar 2.7 Peta kontrol 3-sigma proporsi kesalahan proses pengisian formulir..27 Gambar 3.1 Diagram alir kerangka penelitian.......................................................47 Gambar 4.1 Diagram SIPOC.................................................................................67 Gambar 4.2 Operation process chart.....................................................................68 Gambar 4.3 Diagram pareto tingkat kecacatan produk..........................................70 Gambar 4.4 Diagram pareto hasil analisis CTQ potensial jenis kegagalan...........72 Gambar 4.5 Peta kendali n p proses mounting......................................................81 Gambar 4.6 Peta kendali n p proses basing...........................................................84 Gambar 4.7 Peta kendali R untuk tebal clamp.......................................................87 Gambar 4.8 Peta kendali X untuk tebal clamp.....................................................88 Gambar 4.9 Peta kendali R untuk tinggi mounting................................................91 Gambar 4.10 Peta kendali X untuk tinggi mounting............................................92 Gambar 4.11 Peta kendali X bar tebal clamp berdasarkan konsep Six Sigma Motorola........................................................................................97
Gambar 4.12 Peta kendali X bar tinggi mounting berdasarkan konsep Six Sigma Motorola.........................................................................................98 Gambar 4.13 Diagram fishbone tebal clamp........................................................101 Gambar 4.14 Diagram fishbone tinggi mounting.................................................104 Gambar 4.15Diagram fishbone lubang arbor samping........................................107 Gambar 4.16 Diagram fishbone solder samping/las LIW samping.....................110
