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Jojor Taruli
Universitas Tangerang Raya
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Peningkatan Kualitas Proses Packaging Inner Industri Makanan Melalui Integrasi SPC, RCA, FMEA, Dan Sensor-Based Poka-Yoke Abby Yazid Bustommy; Jojor Taruli; Abimanyu
Science and Education Journal (SICEDU) Vol 5 No 3 (2026): Science and Education Journal 2026
Publisher : LPPM Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/sicedu.v5i3.1128

Abstract

High reject rates in the inner packaging process remain a critical issue in the food manufacturing industry because they reduce product quality, increase production costs, and lower operational efficiency. This study aims to identify the root causes of product rejects and evaluate the effectiveness of an integrated quality improvement framework combining Statistical Process Control (SPC), Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), and sensor-based Poka-Yoke at PT CANDY JTK. A quantitative case study was conducted using production data from July–December 2025 as the baseline period and January–June 2026 as the post-improvement evaluation period. SPC was applied to monitor process stability, RCA to identify root causes, FMEA to prioritize risks based on the Risk Priority Number (RPN), and sensor-based Poka-Yoke to prevent process errors. The proposed framework reduced monthly rejects by 28.36%, from 53,500 kg to 38,330 kg, lowered the reject rate from 4.31% to 3.05%, increased production by 1.41%, and generated estimated cost savings of approximately IDR 303.4 million per month. These findings demonstrate that the integrated framework effectively improves process quality and operational efficiency in food manufacturing.
Penerapan Statistical Process Control (SPC), Root Cause Analysis (RCA), Dan Poka-Yoke Berbasis Sensor Otomatis Untuk Mengurangi Reject Inner Permen Pada Proses Packaging Di PT Candy JTK Jojor Taruli; Abby Yazid Bustommy; Abimanyu Abimanyu
Science and Education Journal (SICEDU) Vol 5 No 3 (2026): Science and Education Journal 2026
Publisher : LPPM Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/sicedu.v5i3.1093

Abstract

Hasil penelitian menunjukkan bahwa Mesin C memiliki tingkat reject tertinggi sebesar 4,05% dengan rata-rata reject 53.500 kg per bulan dan kerugian mencapai Rp3.945.000.000 per bulan. Analisis Diagram Pareto mengidentifikasi permen pecah sebagai jenis reject terbesar (53,72%), diikuti sambungan inner (46,28%). Analisis Root Cause Analysis (RCA) menunjukkan bahwa penyebab utama reject adalah penumpukan permen pada jalur produksi akibat sensor yang tidak mampu mendeteksi aliran permen secara optimal saat kecepatan mesin ditingkatkan untuk memenuhi target produksi. Sebagai solusi, diusulkan penerapan Poka-Yoke berbasis otomatisasi melalui pemasangan sensor otomatis, sistem alarm, dan mekanisme automatic stop untuk mencegah penumpukan permen. Implementasi usulan ini diharapkan dapat menurunkan tingkat reject, mengurangi kerugian produksi, meningkatkan kualitas produk, serta meningkatkan efisiensi proses produksi secara berkelanjutan di PT Candy JTK.
Co-Authors Abby Yazid Bustommy Abby Yazid Bustommy Abimanyu Abimanyu Abimanyu