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
xv
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
xvii
BAB VI PENUTUP ...............................................................................................133 6.1
Kesimpulan 133
6.2
Saran ...........................................................................................................13 5
DAFTAR PUSTAKA LAMPIRAN
xviii
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
xx
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
xiii
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
xii
