Usulan Rancangan Perbaikan Untuk Meminimasi Defect Inklusi Pasir (ip) Pada Proses Pencetakan Shoulder For E-clip Di Pt. Pindad Dengan Metode Dmaic

Ayu Vita Rastiti, Wiyono Wiyono, Widia Juliani

Abstract

Abstrak PT. Pindad merupakan salah satu perusahaan dibawah naungan BUMN yang memproduksi produk militer dan komersial di Indonesia, salah satunya memproduksi komponen perkeretaapian seperti produk shoulder, base plate dan e-clip. Berdasarkan data historis pada periode Januari 2017 – Desember 2018, diketahui produk shoulder memiliki rata-rata defect paling tinggi dan melebihi batas toleransi yang ditetapkan perusahaan. Toleransi produk defect yang ditetapkan perusahan sebesar 2%, sementara produk shoulder memiliki rata-rata defect sebesar 5,22%. Jenis defect inklusi pasir merupakan salah satu jenis defect yang sering terjadi. Maka dari itu penelitian akan berfokus terhadap proses yang menyebabkan defect inklusi pasir menggunakan metode Six Sigma dengan tahap DMAIC. Terdapat 6 buah CTQ yang diperoleh dari hasil kuesioner delphi untuk tahap definisi masalah. Pada tahap measure dilakukan perhitungan stabilitas proses menggunakan peta kendali P dengan memastikan data berada di dalam batas kendali, dan perhitungan kapabiltas proses untuk menentukan nilai DPMO dan nilai sigma. Nilai sigma yang diperoleh sebesar 4,35 dan masih perlu dilakukan peningkatan agar mendekati 6 sigma. Tahap analyze dilakukan menggunakan fishbone diagram dan 5 why’s yang kemudian didapatkan faktor man, method, cetakan dan material sebagai akar penyebab masalah. Selanjutnya dilakukan analisis FMEA untuk menentukan prioritas perbaikan melalui nilai RPN yang tertinggi. Usulan perbaikan yang dilakukan pada tahap improve yaitu perancangan alarm display dengan Poka-yoke, pembuatan penjadwalan pemeliharaan dan pengecekan pipa air sand mixer dan pembuatan display sebagai pengingat pengecekan gatting system. Kata kunci: Kata Kunci: Shoulder, Inklusi Pasir, Six sigma, DMAIC, CTQ, Poka-yoke Abstract PT. Pindad is one of the companies under the auspices of SOEs that produce military and commercial products in Indonesia, one of which is producing railway components such as shoulder products, base plates and e-clips. Based on historical data period January 2017 - December 2018, it is known that shoulder products have the highest defect average and exceed the tolerance limit set by the company. The defect product tolerance set by the company is 2%, while the shoulder product has an average defect of 5.22%. Based on historical data in the period January 2017 - December 2018, shoulder products have the highest average defect and exceed the tolerance limit set by the company. The defect product tolerance set by the company is 2%, while the shoulder product has an average defect of 5.22%. Defect of sand inclusion is one type of defect that often occurs. Therefore, the research will focus on the process that causes defect of sand inclusion using the Six Sigma method with the DMAIC stage. There are 6 CTQs obtained from the results of the Delphi questionnaire for defining the problem. In the measure stage, calculation of process stability is carried out using p-control chart by ensuring the data is within the control limit, and calculation of process capability to determine the DPMO value and sigma value. Sigma value is 4.35 and still needs to be increased to approach 6 sigma. Analyze phase uses fishbone diagram and 5 why so that there are man, method, machine and material factors as the root cause of the problem. After that, FMEA analysis to determine the priority of improvement through the highest RPN value. Proposed improvements in the phase are designing alarm displays with Poka-yoke, making scheduling maintenance and checking of sand mixer water pipes and making display as a reminder of checking gatting systems. Keywords: Shoulder, Sand Inclusion, Six sigma, DMAIC, CTQ, Poka-yoke

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