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All Journal FaST : Jurnal Sains dan Teknologi
Sialahi, Rudy Vernando
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Computer Science & IT Environmental Science

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PENERAPAN DMAIC DALAM UPAYA MENURUNKAN DEFECT PADA PROSES GREEN TIRE SERVICE (GTS) SIZE LIGHT TRUCK DI PT XYZ [IMPLEMENTATION OF DMAIC TO REDUCE DEFECTS IN THE GREEN TIRE SERVICE (GTS) PROCESS FOR LIGHT TRUCK SIZES AT PT XYZ] Sialahi, Rudy Vernando; Pasaribu, Deotemanta
FaST - Jurnal Sains dan Teknologi (Journal of Science and Technology) Vol. 8 No. 1 (2024): NOVEMBER
Publisher : Universitas Pelita Harapan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.19166/jstfast.v8i2.8128

Abstract

PT XYZ is a company engaged in the manufacturing industry which produces tires. The problem faced by the company is related to the production process which still produces defective products that exceed the target of the key performance indicators (KPI) set by the company. This research analyzes and applies DMAIC (Define, Measure Analyze, Improve, Control) to improve product quality. With Stage D (Define) to find out the process flow, making SIPOC (Supplier-Input- Process-Output- Customer), and knowing the types of defects in the GTS (green tire service) process. At stage M (Measure), measurements are carried out using a Pareto diagram to determine the type of defect and the machine with the highest level of defect that will need to be repaired. In stage A (Analyze) the cause of the problem is searched using a fishbone diagram. After the cause of the defect is known, stage I (Improve) is carried out. At this stage, the root of the problem that has been found and explained in the analyze stage is repaired. After repairs have been carried out, stage C (Control) is carried out by creating an SOP (Standard Operating Procedure) for using the VTT-1 machine, a checksheet for machine cleanliness, and a checksheet for changing gloves. In this research, it is known that the defect crease on the VTT(Venting)-1 machine with a DPMO value of 40.36 with a sigma level of 5.43 before the application of DMAIC, after the application of DMAIC the defect crease on the VTT-1 machine decreased to 82% with a DPMO value of 7.25 with a level of sigma 5.84.Bahasa Indonesia Abstract:PT XYZ merupakan perusahaan yang bergerak dalam bidang industri manufaktur yang memproduksi ban. Permasalahan yang dihadapi perusahaan adalah terkait proses produksi yang masih membuat produk defect overtarget dari key performance indicator (KPI) yang ditetapkan oleh perusahaan. Penelitian ini melakukan analisis dan penerapan DMAIC untuk memperbaiki kualitas produk. Dengan Tahap D (Define) untuk mengetahui alur proses, Pembuatan SIPOC, dan mengetahui jenis defect pada proses GTS. Pada tahap M (Measure) dilakukan pengukuran dengan diagram pareto untukmengetahui jenis defect dan mesin dengan tingkat kecacatan yang paling tinggi yang nantinya perlu adanya perbaikan. Pada tahap A (Analyze) dilakukan pencarian penyebab masalah dengan menggunakan fishbone diagram. Setelah diketahui penyebab terjadinya defect, dilakukan tahap I (Improve) pada tahap ini dilakukan perbaikan akar masalah yang telah ditemukan dan dijelaskan pada tahap analyze. Setelah dilakukan perbaikan, tahap C (Control) dilakukan dengan membuat SOP penggunaan mesin VTT-1, checksheet kebersihan mesin, dan checksheet pergantian sarung tangan. Pada penelitian ini di ketahui bahwa defect crease padamesin VTT-1 dengan nilai DPMO 40,36 dengan tingkat sigma 5,43 sebelum penerapan DMAIC, setelah penerapan DMAIC defect crease pada mesin VTT-1 turun hingga 82 % dengan nilai DPMO 7,25 dengan tingkat sigma 5,84 
Perancangan dan Implementasi Electronic TPM (E-TPM) Berbasis Website dengan QR Code pada Mesin Tire Final Inspection di PT XYZ: [Design and Implementation of a Website-Based Electronic TPM (E-TPM) with QR Codes on The Tire Final Inspection Machine at PT XYZ] Sialahi, Rudy Vernando; Rachman, Rahardyan
FaST - Jurnal Sains dan Teknologi (Journal of Science and Technology) Vol. 9 No. 1 (2025): NOVEMBER
Publisher : Universitas Pelita Harapan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.19166/jstfast.v9i2.10375

Abstract

In the Industrial Revolution 4.0, continuous innovation is crucial for companies striving to achieve their vision and mission. One key initiative is implementing Total Productive Maintenance (TPM). PT XYZ, however, encounters challenge due to its ongoing use of conventional, paper-based methods. These methods have numerous drawbacks, such as incomplete documentation of machine damage, outdated information caused by maintenance department oversights, extended data retrieval times, and the risk of document loss or damage. To overcome these issues, an innovative transition was made from a paper-dependent system to a digital, web-based platform to enhance TPM's effectiveness. Data was collected through direct field observation and processed using the SMART (Specific, Measurable, Achievable, Relevant, Timebound) methodology to accurately identify problems and solutions. A web-based application named E-TPM was developed, utilizing the PHP programming language, the CodeIgniter framework, a MySQL database, and a straightforward, user-friendly interface designed with Bootstrap 5.0. This digital shift offers substantial benefits, including real-time management of machinery damage data, improving TPM monitoring efficiency. Digital data storage reduces the risk of falsification or loss, as information is centrally located. Moreover, E-TPM implementation has led to a significant reduction in paper costs, approximately Rp. 495,000 per year, due to the elimination of paper-based TPM tags that are prone to damage or loss. Finally, access to precise data and in-depth analysis enables management to make better-informed decisions regarding maintenance strategies. Bahasa Indonesia Abstract: Dalam era revolusi industri 4.0, inovasi menjadi kunci bagi perusahaan dalam mencapai visi dan misi mereka. Salah satu inovasi tersebut adalah penerapan Total Productive Maintenance (TPM). Namun, PT XYZ masih mengandalkan sistem konvensional berbasis kertas yang memiliki berbagai kelemahan seperti pencatatan kerusakan mesin yang tidak lengkap, risiko data usang karena pembaruan lambat, pencarian data yang membutuhkan waktu lama, serta risiko kehilangan atau kerusakan dokumen. Sebagai solusi, metode paper-based digantikan dengan sistem digital melalui pengembangan situs web untuk mengoptimalkan TPM. Data dikumpulkan melalui observasi lapangan dan dianalisis menggunakan metode SMART (Specific, Measurable, Achievable, Relevant, Timebound) untuk memastikan solusi yang efektif. Selanjutnya, aplikasi berbasis web yang dinamakan E-TPM dikembangkan menggunakan PHP, dengan framework CodeIgniter, database MySQL, dan desain antarmuka yang mudah digunakan dengan Bootstrap 5.0. Transformasi digital ini memungkinkan pengelolaan data kerusakan mesin secara real-time, meningkatkan efisiensi pengawasan kegiatan TPM. Penyimpanan data secara digital mengurangi risiko pemalsuan dan kehilangan data. Penerapan E-TPM juga berdampak positif pada penghematan biaya hingga Rp 495.000 per tahun dengan mengurangi penggunaan kertas untuk tag TPM. Dengan data yang akurat, manajemen dapat lebih efektif dalam merumuskan strategi pemeliharaan.
Co-Authors Pasaribu, Deotemanta Rachman, Rahardyan