IMPLEMENTASI PENGENDALIAN KUALITAS PADA PRODUK HALF AB OUTER COMP K 60 R MENGGUNAKAN METODE SIX SIGMA DI PT SJM

Abstract

Abstrak

PT. Sebastian Jaya Metal Plant Tegal merupakan perusahaan manufaktur otomotif yang memproduksi Half A/B Outer Comp K60R. Kendala utama dalam produksi adalah tingginya jumlah produk cacat pada proses welding, diperburuk oleh keterbatasan tenaga kerja di Departemen Quality Control (QC). Untuk mengatasi permasalahan ini, penelitian ini menerapkan metode Six Sigma, Seven Tools, dan FMEA guna meningkatkan kualitas produk dan mengurangi cacat. Dari 116.092 unit yang diinspeksi, ditemukan 2.298 produk NG (Not Good), dengan DPMO sebesar 1979,465 dan nilai sigma 4,38142, menempatkan kualitas produksi perusahaan pada level sigma 4 hingga 5, yang tergolong sangat baik. Analisis kualitas menunjukkan bahwa yield produk mencapai 99,802%, dengan throughput yield sebesar 98,021%. Pada tahap analyze, identifikasi jenis cacat dilakukan menggunakan Seven Tools, menghasilkan nilai RPN sebesar 810 melalui metode FMEA, serta dianalisis lebih lanjut dengan fishbone diagram. Langkah perbaikan (improve) menargetkan peningkatan 26,976% untuk mencapai level sigma 6, sedangkan tahap control diterapkan untuk menjaga kualitas produk tetap stabil. Implementasi metode ini diharapkan dapat meningkatkan kualitas produksi, mengurangi tingkat cacat, dan memperkuat daya saing PT. Sebastian Jaya Metal di industri otomotif.

Kata Kunci: Six Sigma, DMAIC, Seven Tools, Pengendalian Kualitas, Industri Otomotif

Abstract

PT. Sebastian Jaya Metal Plant Tegal is an automotive manufacturing company that produces the Half A/B Outer Comp K60R. The main challenge in production is the high number of defective products in the welding process, exacerbated by the limited workforce in the Quality Control (QC) Department. To address this issue, this study applies the Six Sigma, Seven Tools, and FMEA methodologies to improve product quality and reduce defects. Out of 116,092 inspected units, 2,298 were classified as Not Good (NG), resulting in a Defects Per Million Opportunities (DPMO) of 1979.465 and a sigma level of 4.38142, positioning the company's production quality within sigma levels 4 to 5, which is considered highly satisfactory. Quality analysis indicates a product yield of 99.802% and a throughput yield of 98.021%. During the analyze phase, defect types were identified using the Seven Tools, leading to an RPN value of 810 through FMEA analysis, and further examined using the fishbone diagram. The improvement phase aims for a 26.976% increase to achieve sigma level 6, while the control phase is implemented to ensure product quality remains stable. The implementation of these methodologies is expected to enhance production quality, minimize defect rates, and strengthen PT. Sebastian Jaya Metal’s competitiveness in the automotive industry.

Keyword: Six Sigma, DMAIC, Seven Tools, Quality Control, Automotive Industry