DAFTAR ISI
HALAMAN JUDUL ........................................................................................................
i
HALAMAN PERNYATAAN...........................................................................................
ii
SURAT KETERANGAN SELESAI ................................................................................. iii HALAMAN PENGESAHAN PEMBIMBING.................................................................. iv HALAMAN PENGESAHAN PENGUJI........................................................................... v HALAMAN PERSEMBAHAN ........................................................................................ vi HALAMAN MOTTO......................................................................................................... vii KATA PENGANTAR......................................................................................................... viii ABSTRAKSI ...................................................................................................................... x DAFTAR ISI ....................................................................................................................... xi DAFTAR TABEL ............................................................................................................... xiv DAFTAR GAMBAR ........................................................................................................... xvi BAB I
PENDAHULUAN 1.1 Latar Belakang Masalah ........................................................................ 1 1.2 Rumusan Malasah ................................................................................. 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 2.2 Pengertian Tentang Pengendalian .......................................................... 10 2.3 Pengertian Tentang Pengendalian Kualitas ........................................... 11 2.4 Pengertian Six Sigma ............................................................................. 11 2.5 Konsep Six Sigma Motorola .................................................................. 13 2.6 Konsep Six Sigma dalam Manufacturing .............................................. 15 2.7 Metodologi Six Sigma ........................................................................... 16 2.8 Tools Dalam Six Sigma ......................................................................... 17 2.8.1 CTQ (Critical to Quality) ....................................................... 17 2.8.2 Diagram SIPOC ...................................................................... 18 2.8.3 Analisis DPMO dan tingkat sigma ......................................... 19 xi
2.8.4 Peta Kendali (Control Chart) ................................................. 21 2.8.5 Diagram pareto ....................................................................... 27 2.8.6 Diagram fishbone ................................................................... 30 2.8.7 Kapabilitas Proses .................................................................. 30 2.8.8 Indeks Kapabilitas proses ....................................................... 31 2.8.9 Stabilitas Proses ..................................................................... 32 2.9 Metode 5W+1H ..................................................................................... 33 BAB III
METODE PENELITIAN 3.1 Objek Penelitian .................................................................................... 34 3.2 Identifikasi Masalah dan Tujuan Penelitian .......................................... 36 3.3 Perumusan masalah ........... ................................................................... 36 3.4 Kajian Literatur . ................................................................................... 36 3.5 Metode Pengumpulan Data ................................................................... 36 3.6 Pengolahan Data .................................................................................... 37
BAB IV
3.6.1 Tahap Define ..........................................................................
38
3.6.2 Tahap Measure .....................................................................
38
3.6.3 Tahap Analyze ......................................................................
38
3.6.4 Tahap Improvement .............................................................
39
3.5 Analisis Data .......................................................................................
39
3.6 Kesimpulan dan Saran ........................................................................
39
PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Profil perusahaan ................................................................................. 40 4.1.1 Identitas Perusahaan .............................................................. 40 4.1.2 Disiplin Kerja ........................................................................ 40 4.1.3 Struktur Organisasi ............................................................... 41 4.1.4 Proses Produksi ..................................................................... 42 4.2 Pengumpulan Data ............................................................................... 44 4.2.1 Data variabel ......................................................................... 44 4.2.2 Data Atribut .......................................................................... 50 4.3 Pengolahan Data .................................................................................. 51 4.3.1 Tahap Define (Definisi) ........................................................ 51 4.3.2 Tahap Measure ...................................................................... 55 4.3.3 Tahap Analyze ....................................................................... 91
BAB V
PEMBAHASAN xii
5.1 Analisis data Variabel ........................................................................... 103 5.2 Analisis Stabilitas dan Kapabilitas Proses ........................................... 106 5.3 Analisis Data Atribut ............................................................................. 108 5.4 Analisis Sumber dan Akar Penyebab Kecacatan Produk....................... 109 5.5 Tindakan dengan 5W+1H ..................................................................... 112 BAB VI
KESIMPULAN DAN SARAN 6.1 Kesimpulan ............................................................................................ 114 6.2 Saran .................................................................................................... 115
DAFTAR PUSTAKA LAMPIRAN
xiii
DAFTAR TABEL Tabel 2.1 Perbedaan true 6-sigma dengan motorola 6-sigma .......................................
15
Tabel 2.2 Contoh perhitungan untuk data atribut ..........................................................
19
Tabel 2.3 Contoh perhitungan untuk data variabel .......................................................
20
Tabel 2.4 Daftar Nilai Konstanta ...................................................................................
24
Tabel 4.1 Variabel Panjang Ibu Jari Sarung Tangan Golf .............................................
45
Tabel 4.2 Variabel Panjang Jari Telunjuk Sarung Tangan Golf ....................................
46
Tabel 4.3 Variabel Panjang Jari Tengah Sarung Tangan Golf .......................................
46
Tabel 4.4 Variabel Panjang Jari Manis Sarung Tangan Golf ........................................
47
Tabel 4.5 Variabel Panjang Jari Kelingking Sarung Tangan Golf ................................
48
Tabel 4.6 Variabel Lebar Pergelangan Tangan Sarung Tangan Golf .............................
49
Tabel 4.7 Data Atribut Sarung Tangan Golf Bulan September 2015 .............................
50
Tabel 4.8 Tabel Critical to Quality (CTQ) .....................................................................
55
Tabel 4.9 Pengolahan Data atribut perhitungan DPMO dan Tingkat sigma ..................
57
Tabel 4.10 Perhitungan DPMO dan Tingkat Sigma data Atribut....................................
58
Tabel 4.11 Data Pengolahan Peta kendali p ....................................................................
59
Tabel 4.12 Pengolahan Data untuk Variabel Panjang Ibu Jari ........................................
62
Tabel 4.13 Perhitungan DPMO dan Nilai Sigma Variabel Panjang Ibu Jari ..................
63
Tabel 4.14 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel P. Ibu Jari ....
65
Tabel 4.15 Pengolahan Data untuk Variabel Panjang Jari Telunjuk ...............................
67
Tabel 4.16 Perhitungan DPMO dan Nilai Sigma Variabel Panjang Jari Telunjuk ..........
68
Tabel 4.17 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel P. Telunjuk ... 70 Tabel 4.18 Pengolahan Data untuk Variabel Panjang Jari Tengah ..................................
72
Tabel 4.19 Perhitungan DPMO dan Nilai Sigma Variabel Panjang Jari Tengah .............
73
Tabel 4.20 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel P. J. Tengah ... 75 Tabel 4.21 Pengolahan Data untuk Variabel Panjang Jari Manis ...................................... 77 Tabel 4.22 Perhitungan DPMO dan Nilai Sigma Variabel Panjang Jari Manis ................ 78 Tabel 4.23 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel P. J. Manis ..... 80 Tabel 4.24 Pengolahan Data untuk Variabel Panjang Jari Kelingking .............................. 82 Tabel 4.25 Perhitungan DPMO dan Nilai Sigma Variabel Panjang Jari Kelingking ........ 83 Tabel 4.26 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel P. Kelingking... 85 Tabel 4.27 Pengolahan Data untuk Variabel Lebar Pergelangan Tangan .......................... 87 Tabel 4.28 Perhitungan DPMO dan Nilai Sigma Variabel Lebar Pergelangan Tangan .... 88 xiv
Tabel 4.29 Cara Memperkirakan DPMO dan Kapabilitas Sigma Variabel L. Pergelangan.. 90 Tabel 5.1 Kapabilitas Proses produksi Sarung Tangan Golf ............................................. 98 Tabel 5.2 Uji hipotesis chi-kuadrat data variabel ............................................................... 100
xv
DAFTAR GAMBAR
Gambar 2.1 Konsep Six Sigma Motorola dengan Distribusi normal bergeser 1,5-sigma ... 14 Gambar 2.2 Diagram Proses SIPOC ................................................................................... 18 Gambar 2.3 Contoh diagram pareto .................................................................................... 29 Gambar 2.4 Contoh diagram fishbone ................................................................................ 30 Gambar 3.1 Diagram Alur Penelitian ................................................................................. 35 Gambar 4.1 Struktur organisasi Pt. Sport Glove Indonesia ................................................ 41 Gambar 4.2 Diagram Alir Proses produksi ......................................................................... 42 Gambar 4.3 Diagram SIPOC .............................................................................................. 51 Gambar 4.4 Diagram Persentase Masing-masing cacat ..................................................... 56 Gambar 4.5 Grafik pola DPMO Data Atribut .................................................................... 58 Gambar 4.6 Grafik pola Nilai Kapabilitas Sigma data atribut ............................................ 58 Gambar 4.7 Peta Kendali p data atribut .............................................................................. 64 Gambar 4.8 Grafik DPMO Variabel Panjang Ibu Jari ........................................................ 64 Gambar 4.9 Grafik Sigma Variabel Panjang Ibu Jari ......................................................... 62 Gambar 4.10 Grafik DPMO Variabel Panjang Jari Telunjuk ............................................. 67 Gambar 4.11 Grafik Sigma Variabel Panjang Jari Telunjuk .............................................. 67 Gambar 4.12 Grafik DPMO Variabel Panjang Jari Tengah ............................................... 74 Gambar 4.13 Grafik Sigma Variabel Panjang Jari Tengah ................................................. 74 Gambar 4.14 Grafik DPMO Variabel Panjang Jari Manis .................................................. 79 Gambar 4.15 Grafik Sigma Variabel Panjang Jari Manis .................................................... 79 Gambar 4.16 Grafik DPMO Variabel Panjang Jari Kelingking ......................................... 84 Gambar 4.17 Grafik Sigma Variabel Panjang Jari Kelingking ........................................... 84 Gambar 4.18 Grafik DPMO Variabel Lebar Pergelangan Tangan ..................................... 89 Gambar 4.19 Grafik Sigma Variabel Lebar Pergelangan Tangan ....................................... 89 Gambar 4.20 Grafik Peta Kendali ̅ Variabel Panjang Ibu Jari .......................................... 92 Gambar 4.21 Grafik Peta Kendali ̅ Variabel Panjang Jari Telunjuk ............................... 94
xvi
Gambar 4.22 Grafik Peta Kendali ̅ Variabel Panjang Jari Tengah ................................. 96 Gambar 4.23 Grafik Peta Kendali ̅ Variabel Panjang Jari Manis ................................... 97 Gambar 4.24 Grafik Peta Kendali ̅ Variabel Panjang Jari Kelingking ........................... 99 Gambar 4.25 Grafik Peta Kendali ̅ Variabel Lebar Pergelangan Tangan ...................... 101 Gambar 5.1
Diagram Fishbone Analisis penyebab cacat data atribut ........................... 109
Gambar 5.2
Diagram Fishbone Analisis penyebab cacat data variabel ......................... 111
xvii
