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Rusindiyanto Rusindiyanto
UPN "Veteran" Jawa Timur, Indonesia

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Analysis Of Defect Waste Reduction In Metal Forming Process Using Lean Six Sigma Hassan Rahmatillah; Rusindiyanto Rusindiyanto
ITEJ (Information Technology Engineering Journals) Vol. 10 No. 1 (2025): June
Publisher : Pusat Teknologi Informasi dan Pangkalan Data IAIN Syekh Nurjati Cirebon

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24235/itej.v10i1.203

Abstract

This study investigates the reduction of defect waste in the metal forming process at PT XYZ, with a specific focus on the production of the reff D nose component. Recognizing the critical importance of quality in the aerospace industry, where even minimal defects can compromise safety and operational integrity, this research applies Lean Six Sigma methodology to address the observed defect rate, which averaged 4.6% over the period 2018–2023—significantly exceeding the company’s target of 1%. A comprehensive DMAIC (Define, Measure, Analyze, Improve, Control) framework was employed to systematically identify, quantify, and analyze the sources of defects. Data were collected from both primary sources, including direct observations and stakeholder interviews, and secondary sources such as production records and defect reports. Advanced tools such as SIPOC diagrams, Pareto analysis, Interpretive Structural Modeling (ISM), and the 5 Whys method for Root Cause Analysis (RCA) were utilized to determine the critical factors affecting process performance. The analysis revealed that issues related to raw material quality, suboptimal process parameter settings, machine conditions, operator competency, and production environment stability are the primary contributors to the elevated defect rates. Based on these findings, targeted improvement strategies were proposed to optimize process efficiency and enhance product quality.
A Analysis of Preventive Maintenance Schedule of Xym1900 Vertical Roller Mill Crusher Machine using MTBF (Mean Time Between Failures) Method Based on RCA (Root Cause Analysis) Muhammad Alfin; Rusindiyanto Rusindiyanto
ITEJ (Information Technology Engineering Journals) Vol. 10 No. 1 (2025): June
Publisher : Pusat Teknologi Informasi dan Pangkalan Data IAIN Syekh Nurjati Cirebon

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24235/itej.v10i1.205

Abstract

The reliability and performance of heavy machinery are critical to maintaining consistent production in the cement industry. This study analyzes the preventive maintenance schedule of the XYM1900 Vertical Roller Mill crusher machine at PT XYZ, where frequent breakdowns have contributed to production inefficiencies and increased operational costs. The research employs the Mean Time Between Failures (MTBF) method to evaluate the reliability of key machine components and identify optimal maintenance intervals. Additionally, Root Cause Analysis (RCA) is used to trace the underlying causes of recurring failures. Maintenance and failure data were collected over a one-year period to calculate MTBF values for critical components, including the grinding roller, hydraulic system, and gearbox. RCA findings indicate that improper lubrication, delayed part replacements, and environmental factors such as dust contamination are the primary contributors to equipment failure. Based on the analysis, revised maintenance schedules were proposed to reduce unplanned downtime and extend component life. The results demonstrate that implementing a data-driven preventive maintenance plan can significantly enhance equipment reliability and support operational efficiency.
A Application of Six Sigma and FMEA Methods for Defect Reduction in Woven Bag Production Faris Yasin Rochmatullah; Rusindiyanto Rusindiyanto
ITEJ (Information Technology Engineering Journals) Vol. 10 No. 1 (2025): June
Publisher : Pusat Teknologi Informasi dan Pangkalan Data IAIN Syekh Nurjati Cirebon

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24235/itej.v10i1.215

Abstract

This study aims to reduce the number of defects in the production of woven bags, which experiences product defects ranging from 4.1% to 5.4%. The method used is Six Sigma with the DMAIC (Define, Measure, Analyze, Improve, Control) approach to improve product quality. Root cause analysis was carried out using fishbone diagrams and Failure Mode and Effect Analysis (FMEA) which identified four main factors causing defects, namely humans, machines, materials, and methods. The results showed that the defects that had the most effect on the production process were perforated weaving, stretched weaving, and miss print. From the data analyzed for the period January to December 2024, a Defects Per Million Opportunities (DPMO) value of 6,746,655 and a sigma level of 3.97 were obtained, which shows that even though the production process is good enough, there is still room for improvement. Improvement recommendations include increased quality supervision and regular calibration of machines to achieve better quality targets. With the application of the Six Sigma method, it is hoped that the company can achieve a significant reduction in the defect rate and improve overall production performance.
Improving Multi-Floor Factory Facilities Layout Using CRAFT Algorithm Method in UMKM Aneka Songkok Jombang Firda Amalia Putri; Rusindiyanto Rusindiyanto
ITEJ (Information Technology Engineering Journals) Vol. 10 No. 2 (2025): December
Publisher : Pusat Teknologi Informasi dan Pangkalan Data IAIN Syekh Nurjati Cirebon

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24235/itej.v10i2.266

Abstract

Facility layout design is a challenging issue in an industry. UMKM Aneka Songkok is a multi-floor building consisting of several departments. Observations show that the placement of work areas does not take into account the relationships between work stations, does not optimise space utilisation, and has an unsystematic material flow. This causes various problems, such as increased material transfer distances and greater occupational safety risks. To address these issues, facility layout improvements are necessary to enhance production effectiveness and efficiency. This study aims to redesign the facility layout of UMKM Aneka Songkok using the Craft algorithm method to improve the layout design, making the facility layout more effective and efficient, thereby organising the production process and minimising material movement distances between workstations. The research results show a reduction in distance per production run of 109.35 m and a reduction in distance per day of production of 387.3 m. The proposed layout was selected because it reduces material movement distances and improves material flow.
Co-Authors Faris Yasin Rochmatullah Firda Amalia Putri Hassan Rahmatillah Muhammad Alfin