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"Persaingan yang semakin kompetitif di pasar global mendorong PGT Sapuran untuk meningkatkan efisiensi produksi khususnya untuk pemakaian sumber daya yang ada. Kriteria utama pencapaian efisiensi produksi ini diukur dari jumlah lost production yang didefinisikan sebagai selisih antara jumlah aktual bahan baku yang digunakan dengan jumlah aktual barang jadi yang dihasilkan. Semakin besar lost production yang terjadi akan berakibat semakin banyak bahan baku yang hilang dalam proses. Hal ini akan sangat merugikan perusahaan. Oleh karena itu pengendalian dan penekanan terhadap jumlah lost production ini mutlak diperlukan oleh perusahaan. Penelitian ini memfokuskan pada upaya umtuk mencari solusi-solusi yang dpat menurunkan jumlah lost production dengan menggunakan metode Six Sigma. Dengan mengikuti metodologi Six Sigma (Define, Measure, Analyze, Improve, Control), dicari akar permasalahan kejadian lost production dan dilanjutkan dengan mencari solusi yang mungkin.Sebagai hasil penelitian, kinerja perusahaan yang diterjemahkan ke dalam level sigma adalah sebesar 2.3 sigma, dimana nilai ini jauh dari standar minimal kinerja nilai sigma perusahaan secara internasional yaitu 4 sigma. Penyebab utama muncul dari tiga kejadian yaitu material ikut terbuang bersama air dan kotoran, terdapat banyak kotoran pada bahan baku, dan kebocoran di pipa yang menghubungkan mesin satu dengan mesin lain. Sebagai solusi perlu dilakukan beberapa usaha untuk peningkatan dan pengendalian proses.

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An increasing in global market competition forced PGT Sapuran to increase its production eficiency especially in the use of their resource. The main criteria is measured by the number of lost production, wich is defined as the difference between actual total raw material used and the finish good result in a day. As increasing in lost production means lossing more in raw material, it takes effect in reducing the company?s profit. There for an effort to control and minimize lost production number is importantly needed.

This paper focused on finding solutions to reduce the number of lost production using Six Sigma methodology. By following the methodology (Define, Measure, Analyze, Improve, Control), this paper seeks for the root caused of lost production and then find the possible solution.

As the result of the research, the performance of PGT Sapuran is in 2.3 sigma level, wich is far from the standard level performance. The main caused is the material is trown away along with water and waste, the raw material contains lot of waste, and last is leak in pipe. As solution, PGT Sapuran need to do some efforts to increase and maintain its process capability."

"Persaingan yang semakin kompetitif di pasar global telah mendorong PT DAC untuk berusaha meningkatkan efisiensinya khususnya pada pemakaian resource yang ada. Kriteria utama pencapaiannya diukur dari jumlah Lost Productions, yang didefinisikan sebagai selisih antara jumlah actual bahan baku dengan actual barang jadi. Karena semakin besar lost productions berarti semakin banyak kebutuhan bahan baku yang hilang maka akan berakibat merugikan perusahaan. Oleh karena itu pengendalian dan penekanan sampai tingkat sekecil mungkin sangat diperlukan bagi perusahaan. Penelitian ini memfokuskan pada usaha mencari solusi-solusi untuk menurunkan jumlah Lost productions menggunakan metode Six Sigma. Mengikuti metodologi Six Sigma (Define, Measure, Analyze, Improve and Control), penelitian ini mencari akar permasalahan kejadian lost productions dan dilanjutkan dengan mencari solusi yang mungkin. Sebagai hasil penelitian, kinerja perusahaan terhadap kriteria jumlah Lost Productions hanya berada pada Level 3.132. Penyebab utamanya muncul dari waktu penangangan kejadian Lost pada Strand. Sebagai solusi, perlu dilakukan beberapa usaha untuk peningkatan dan pengendalian proses.

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As increasing in global market competitions, forced PT DAC to increase its efficiency, especially in using its resource. Main criteria is measured by number of lost productions, defined as the difference between total actual of raw material and finish good (F/G) result per productions cycle. As Increasing its lost Productions means Lossing in raw material, so it can effect in reducing its profit. Effort to control and minimize lost productions number is needed, importantly. This Paper Focus on finding solutions to reduce Lost Productions using Six Sigma. By applying Six Sigma Metodhology (Define, Measure, Analyze, Improve and Control,) this paper seek root caused of lost Productions event and then find the posible solutions. As a result, PT DAC performance in reducing Lost Productions is only in 3.132 sigma level. Main problem is on the time to finish Lost Strand event. As a solutions, PT DAC must do some efforts to increase and maintain its Process Capability."

"Skripsi ini membahas tentang bagaimana cara mengurangi reject part painting plastic yang ada, yaitu dengan metode Six Sigma yang akan mengetahui bagian penyebabpenyebab mana saja yang sangat berpengaruh terhadap terjadinya cacat pada part painting plastik tersebut. Dan inti dari skripsi ini ialah, bagaimana memperbaiki performa proses dan meningkatkan nilai-nilai metric indeks kemampuan proses. Hasil penelitian menyarankan bahwa harus dilakukan penyediaan spare part serta pembuatan standar pemeriksaan kereta dan penjadwalan pemeriksaan kereta secara periodik dan memberikan training kepada operator supaya operator mengerti standar kualitas dan dapat meningkatkan keahlian.

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This mini thesis explained about how to reduce part painting plastic, that is with six sigma method will find out the most influential causing part to the rejection of the part painting plastic. and the main point of this mini thesis is how to fix the performance process and to increase the metric index values of process capability.

The result of the research suggesting to do the spare part supplying, the making of train checking standard, train checking schedule periodicaly and training, so the operator understand the quality standard and developing their skill."

"Keinginan meningkatkan kinerja proses pembuatan Weight A Steering Handle menjadi dasar yang didukung oleh data yang menunjukan besarnya tingkat defect yang dihasilkan proses. Mayoritas jenis defect yang ditimbulkan dari proses berupa defect yang bersifat visual. Tujuan dari penulisan skripsi ini tiada lain untuk mencari solusi yang tepat dalam mengurangi defect. Skripsi ini menjelaskan bagaimana metoda Six Sigma digunakan dalam memperbaiki proses dalam pembuatan Weight A Steering Handle yang diproduk oleh PT.XYZ. Penerapan metoda DMAIC sebagai inti dari Six Sigma diharapkan akan memberi dampak positif berupa berkurangnya defect yang secara tidak langsung akan menekan biaya kerugian yang ditimbulkan akibat defect.

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A longing for a better process performance in producing Weight A Streering Handle become a basic thinking beside data that show how significant the defect rate that the process have. The most defect that the process have is defect in visual area. The aim of this report is explain how to find the right solution in decreasing the defects.

This report will explain how the Six Sigma method implement in reducing defect in producing Weight A Steering Handle by PT.XYZ. Implementation of the DMAIC method as a core of the Six Sigma hopefully will bring a positive effect to the process performance shown by decreasing in defect which will effect in reducing the cost of quality."

"DMAIC Six Sigma adalah metode peningkatan kualitas yang mengedepankan kepuasan pelanggan. Belakang ini, perusahaan tidak dapat memenuhi permintaan pelanggan dikarenakan barang jadi yang memenuhi standar dibawah jumlah pesanan. Maka dari itu penurunan cacat produksi untuk meningkatkan kualitas produksi minyak goreng dibutuhkan. Penelitian ini dilakukan dengan mengimplementasikan DMAIC Six Sigma untuk mengidentifikasi kebutuhan pelanggan, kondisi perusahaan saat ini , dan juga akar masalah penyebab produk cacat. Analytical Hierarchy Process (AHP) juga digunakan untuk membuat pembobotan importance dan performance setiap akar masalah yang berhasil diidentifikasi di dalam divisi produksi menggunakan metode Dmaic Six Sigma. Dua proses beserta kebutuhan pelanggannya berhasil diidentifikasi. Proses Refinery saat ini beroperasi di 3.43 sigma dan proses Fraksinasi beroperasi di 3.52 sigma. Kejadian cacat tertinggi di proses refinery beserta penyebabnya telah teridentifikasi. Kemudian, Importance dan Performance mereka dipetakan kedalam diagram Importance Performance Analysis (IPA) untuk memfokuskan penelitian pada atribut yang akan memiliki daya ungkit besar ketika diperbaiki. Empat strategi perbaikan telah diusulkan untuk ketiga atribut tersebut untuk meningkatkan kualitas produksi minyak goreng.

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DMAIC Six Sigma is a quality improvement method that revolves around customer satisfaction. Lately, the company cannot fulfill customer orders as finished goods that are in accordance with customer requirements were below orders. Defect reduction to improve the quality of cooking oil production was therefore needed. This research was conducted by applying DMAIC Six Sigma cycle to understand customer requirements, the company’s current condition, as well as the root cause for defective products. Analytical Hierarchy Process (AHP) was also used to weigh the importance and performance of each root cause identified in the production division through DMAIC Six Sigma. There are two major processes identified along with their customer requirements. The refining process is currently operating at 3.43 sigma while the fractioning process is at 3.52 sigma. Highest defect occurrences were identified on the refining process along with each respective root causes. Their importance and performance weight are mapped into an Importance Performance Analysis (IPA) diagram to focus the improvement project on attributes that provide higher leverage when improved. four improvement strategies were proposed for those attributes to improve the quality of cooking production."

"Penelitian ini membahas tentang losses material pada proses pembuatan Open Top Can (OTC). Tujuan dari penelitian ini adalah untuk mengidentifikasi penyebab dan mengurangi losses material. Objek penelitian ini adalah perusahaan yang bergerak dalam bidang makanan dan minuman, sedangkan fokus penelitian pada proses pembuatan OTC yang akan dipakai dalam proses pengalengan produk tersebut. Penelitian ini dianalisis menggunakan metode Six Sigma dengan tahapan Define, Measure, Analyze, Improve, Control (DMAIC). Metode Six Sigma merupakan tahapan peningkatan kualitas untuk mencapai 3,4 kecacatan per satu juta kesempatan. Hasil penelitian ini yaitu 4 penyebab terjadinya losses material yaitu defect OTC, defect lid, defect body can dan juga material sisa. Pengurangan defect OTC sebesar 25.838,50 Defect Per Million Opprtunities (DPMO) dan kenaikan level Sigma sebesar 0,35.

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The focus of this research is the material loss in the process of making Open Top Can (OTC). This research aims to identify the cause and to reduce material loss. The object of this research is a company working in food and beverage field, while the focus of the research is the making process of Open Top Can (OTC) that will be used in the canning process of the product. This research is analyzed using Six Sigma method with Define, Measure, Analyze, Improve, Control (DMAIC) phase. Six Sigma methods are step to increase quality to reach 3.4 defects per million opportunities. The research reveals four causes of material loss - defect OTC, defect lid, defect body can and scraps of material. Reduce the defect OTC up to 25,838.50 Defect Per Million Opportunities (DPMO) and increase the Sigma level up to 0.35."

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"In January 2005, to continuously improving and delivering the customer value, which helping customers and distributors to meet their needs and satisfaction, Company XYZ distributes the VOC (Voice of Customer) to Distributor ABC as a Local Distributor of Company XYZ in Indonesia for Specialty Chemicals Products. The feedback from Distributor ABC indicates that one key point, which considered as very important and prioritized to be improved by Company XYZ is the Order Lead Time.As the response, Company XYZ in Indonesia, lead by Distributor Coordinator of Company XYZ initiates and performs this Six-Sigma Project to reduce the Order Lead Time. Order Lead Time is defined as the amount of time required from the submitted Purchase Order (PO) by Distributor ABC to the time the Distributor ABC received the order. The term and condition of the Order from Distributor ABC to Company XYZ is Free On Board (FOB) Singapore. The scope of the project will be limited to the Consumable Products imported from Manufacturing/Blending Plant located at China, which contribute about 75% of total products ordered by Distributor ABC.The Distributor ABC expects to have fast and on time delivery, in order to have a better management of local inventory in Indonesia, and reducing the inventory level in the warehouse that in return will significantly reduced the inventory cost. To anticipate late delivery to the End Customer, Distributor ABC provides 3 months of inventory level at the warehouse in Indonesia.To find the best solution on how to reduce the Order Lead Time, the problem solving methodology of Six-Sigma DMAIC (Define-Measure-Analyze-Improve-Control) has been using as a tool to find the source of variation, solving the problem, and improving the existing process. The project is based on the baseline data from October 2004 to March 2005 and project implementation from April to September 2005.The Six-Sigma Project result shows that the major problem was occurred due to the availability of the raw material in Company XYZ Blending Plant at China and the availability of products in the Warehouse of Company XYZ at Singapore and China. Thus, as the consequences, the products should be produced "Just in Time" at the Blending Plant in China that obviously prolongs the Order Lead Time, especially when the raw material is not available.Based on the result of Six-Sigma Project, the best solution to reduce the Order Lead Time and to manage the inventory Control is by using a Forecast Order. Forecast Order will help Company XYZ to manage and provide buffer stock at Singapore and China Warehouse and also prepare the raw material in the Blending Plant at China. Since the products are available in the Company XYZ Warehouse, the Order Lead Time to Distributor ABC could be reduced.The implementation of Forecast Order and inventory management has been giving a significant impact on the Order Lead Time. The implementation of the Forecast Order in April till September 2005 shows that the Order Lead time can be reduced from the average of 45 days to 17 days. Distributor ABC is also able to reduce the inventory level at the warehouse in Indonesia from 3 months to 1 month. The inventory cost could be reduced by approximately 73%."

"In the dynamic and competitive realm of global manufacturing, the tire industry stands as a critical pillar supporting automotive safety, performance, and sustainability. With a total market valued that has been increasing since the last few years and an annual global production exceeding 2.5 billion units according to statista as of 2023, and a compound annual growth rate of 3.31%, the tire manufacture operate under rigorous standards to meet diverse consumer demands and regulatory requirements worldwide In this dynamic environment, PT. XYZ plays a significant role as a key player in Indonesia’s tire manufacturing sector. To undertake the broader dynamics of global tire manufacturing and regional competition, PT. XYZ aligns its quality assurance strategis with global industry standards while addressing unique challenges and opportunities in the Indonesia market. This study aims to evaluate the current manufacturing process of radial tire, specifically in the curing process by implementing six sigma methodology and synergizing the DMAIC (Define, Measure, Analyze, Improve, and Control) framework, to discover underlying cause of accidental defect production within the company. Based on the evaluation, it is discovered that the main contributors of defects consist of Leaky Bladder, Pinched Bead, Buckled Bead, Light Inside and Open Mold. To eliminate the current problem occurring within the process, machinery and industry 4.0 tools are developed adapting to the problem type for each company such as leaky bladder detection system, bead repair system, and others.

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Dalam dunia manufaktur global yang dinamis dan kompetitif, industri ban berdiri sebagai pilar penting yang mendukung keselamatan, kinerja, dan keberlanjutan otomotif. Dengan total nilai pasar yang terus meningkat sejak beberapa tahun terakhir dan produksi global tahunan yang melebihi 2,5 miliar unit menurut statista pada tahun 2023, serta tingkat pertumbuhan tahunan gabungan sebesar 3,31%, manufaktur ban beroperasi di bawah standar yang ketat untuk memenuhi permintaan konsumen yang beragam dan persyaratan peraturan di seluruh dunia. Dalam lingkungan yang dinamis ini, PT. XYZ memainkan peran penting sebagai pemain kunci dalam sektor manufaktur ban di Indonesia. Untuk menghadapi dinamika yang lebih luas dari manufaktur ban global dan persaingan regional, PT. XYZ menyelaraskan strategi jaminan kualitasnya dengan standar industri global sekaligus menjawab tantangan dan peluang unik di pasar Indonesia. Penelitian ini bertujuan untuk mengevaluasi proses produksi ban radial saat ini, khususnya pada proses curing dengan mengimplementasikan metodologi six sigma dan mensinergikan kerangka kerja DMAIC (Define, Measure, Analyze, Improve, and Control), untuk menemukan penyebab utama terjadinya cacat produksi yang tidak disengaja di perusahaan. Berdasarkan hasil evaluasi, ditemukan bahwa kontributor utama cacat terdiri dari Leaky Bladder, Pinched Bead, Buckled Bead, Light Inside, dan Open Mold. Untuk menghilangkan masalah yang terjadi dalam proses, mesin dan alat industri 4.0 dikembangkan menyesuaikan dengan jenis masalah di setiap perusahaan seperti sistem deteksi kandung kemih bocor, sistem perbaikan manik-manik, dan lain-lain."

"ABSTRACTPada proses produksi plywood di PT ACDF terdapat peningkatan jumlah defect pada ukuran 8 milimeter dimana untuk dapat menyelesaikan permasalahan tersebut dibutuhkan metode salah satunya metode DMAIC. Dimana metode tersebut menguraikan beberapa kemungkinan dari factor ndash; factor yang dapat mempengaruhi defect, salah satu factor yang mempengaruhi jumlah defect yaitu pada mesin cold press dimana belum adanya setting up mesin yang optimal untuk jumlah tumpukan plywood dan waktu cold press plywood dengan melakukan perhitungan capability process diketahui nilai capability awal apakah capable atau tidak capable dan perhitungan DPMO dari penelitian tersebut perlu dilakukan improvement, berupa improvement setting up mesin cold press dengan mengacu pada counter plot untuk mengetahui persebaran awal defect setelah mengetahui persebaran defect yang paling minimal langkah berikutnya tinggal memasukan input ke mesin cold press dan data hasil output dilakukan pengujian data untuk mengetahui data mana yang akan dijadikan acuan improvement setelah diketahui dihitung nilai capability dan DPMO dan bandingkan dengan sebelumnya pada penelitian ini untuk improvement dilakukan dengan memasukan input waktu cold press di 35 menit dan setelah membandingkan nilai DPMO dan capability process megalami peningkatan dari sebelumnya.

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ABSTRACTIn the production process of plywood in PT ACDF there is an increasing number of defect at size 8 millimeter where to be able to solve the problem needed method one of them DMAIC method. Where the method describes some of the possible factors that can affect the defect, one of the factors that affect the number of defects that is on cold press machine where there is no optimal machine up setting for the amount of plywood pile and cold press plywood time by performing capability process calculation is known the initial capability value is either capable or not capable and DPMO calculation from the research needs to be done improvement, in the form of improvement setting up cold press machine with reference to counter plot to know the initial spread of defect after knowing the spread of defect the most minimum the next step to stay input to cold machine press and data output results are tested data to determine which data will be used as a reference improvement after it is known to calculate the value of capability and DPMO and compare with previous in this research for improvement is done by input input time u cold press at 35 minutes and after comparing DPMO and capability process value has increased from before."