MENGETAHUI KUALITAS PROSES PRODUKSI CORRUGATED CARTON SHEET MENGGUNAKAN METODE FTA DAN FMEA MELALUI FASE DMAIC (Studi Kasus: PT Jawasurya Kencana Indah Semarang)

Abstract

Abstrak

PT Jawasurya Kencana Indah merupakan perusahaan yang berfokus pada produksi corrugated box dan
sheet. Persaingan dalam dunia usaha semakin ketat mendorong perusahaan terus mengembangkan dan
meningkatkan kualitas hasil produksi. Maksimal waste produksi yang ditetapkan oleh perusahaan yaitu
sebesar 4,80% tetapi pada bulan Desember 2021 proses produksi menghasilkan waste 7,51% dimana 4.46%
berasal dari waste bad sheet yang terjadi pada bagian corrugating. Penelitian menggunakan metode Fault
Tree Analysis (FTA) untuk mengidentifikasi akar masalah dan Failure Mode and Effect Analysis (FMEA)
untuk mengetahui Risk Priority Number melalui fase Define, Measure, Analysis, Improve, Control (DMAIC).
Berdasarkan hasil penelitian pada proses corrugating terdapat empat jenis defect yaitu krepek, skor variasi,
potongan cengis dan gembos dimana krepek memiliki persentase tertinggi sebesar 64,85%. Kegagalan
potensial yang dapat menjadi akar masalah yaitu viskositas lem terlalu rendah, mesin glue roll membawa
lem tidak stabil, tension break kurang optimal, pemasangan roll kertas terlalu lama, dan air steam tidak dapat
keluar. Dari analisis FMEA diperoleh mesin glue roll membawa lem tidak stabil akibat glue roll aus memiliki
nilai RPN tertinggi sebesar 125. Usulan perbaikan yang diberikan yaitu melakukan pengecekan kesesuaian
standar kualitas bahan baku lem, melakukan pengecekan glue roll, silinder break, selang angin serta penyalur
uap untuk meminimalkan potensi terjadinya defect.

Kata Kunci: corrugated carton sheet; defect; DMAIC; FMEA; FTA

Abstract

[Title: Knowing the Quality of Corrugated Carton Sheet Production Processes Using FTA and FMEA
Methods Through the DMAIC Phase (Case Study: PT Jawasurya Kencana Indah Semarang)]PT
Jawasurya Kencana Indah is a company that focuses on the production of corrugated box and sheet.
Competition in the business world is getting tighter, encouraging companies to continue to develop and
improve the quality of production results. The maximum production waste set by the company is 4.80% but
in December 2021 the production process produced 7.51% waste of which 4.46% came from bad sheet waste
that occurred in the corrugating section. The research uses the Fault Tree Analysis (FTA) method to identify
the root of the problem and Failure Mode and Effect Analysis (FMEA) to determine the Risk Priority Number
through the Define, Measure, Analysis, Improve, Control (DMAIC) phase. Based on the results of the
research on the corrugating process, there are four types of defects, namely crepe, variation score, cengis
piece and gembos where crepe has the highest percentage of 64.85%. Potential failures that can be the root
of the problem are glue viscosity is too low, glue roll machine carrying glue is not stable, tension break is
not optimal, paper roll installation is too long, and steam water cannot escape. From the FMEA analysis, it
is obtained that the glue roll machine carrying unstable glue due to glue roll wear has the highest RPN value
of 125. The proposed improvements are checking the suitability of the glue raw material quality standards,
checking the glue roll, cylinder break, wind hose and steam distributor to minimize the potential for defects.

Keywords: corrugated carton sheet; defect; DMAIC; FMEA; FTA