Usulan Perbaikan dalam Mengurangi Kecacatan Produk Menggunakan Metode Lean Six Sigma dan Process Activiy Mapping (PAM) di PT XYZ

Abstract

Competition in the manufacturing and service industries is increasingly competitive, therefore the quality of a product must also be considered in order to compete in the existing market. PT. XYZ is a company engaged in the production of electrical panels for factories and housing. PT. XYZ uses the main raw material, namely steel plate, the thickness sizes used are 1.4 mm, 1.6 mm and 1.8 mm thickness. From observations made on the electrical panel production process, there was waste in the form of waiting time activities with a total non-value added time of 9.87 minutes and an average percentage of product defects of 10.54% which is still above the company's tolerance of 5%. . The purpose of this research is to reduce waste to improve product quality. The method used is lean six sigma and process activity mapping which aims to reduce the number of defective products and non-value added activities. The six sigma lean consists of DMAIC (Define, Measure, Analyze, Improve, Control) stages. Proposed improvements use the FMEA method with a Risk Priority Number (RPN) assessment. As for the improvements made to the identification of human, material, machine, and method causal factors. From the estimation results, the sigma level is 3.82 to 4.21 with a minimum application of 60%. In addition, in non-value added activities, 3 activities were eliminated resulting in a reduction in manufacturing lead time of 9.87 minutes