Pengurangan Produk Off-grade pada Produksi Teh Hijau di PT XYZ
Abstract
Beberapa tingkat kualitas teh hijau yang dihasilkan oleh PT XYZ, yaitu MT
(daun utuh/peko), bubuk, tulang, dan sweeping (limbah). Bubuk, tulang, dan
sweeping dikategorikan menjadi produk off-grade. Sweeping merupakan jenis
produk off-grade tertinggi yang terdapat pada hasil akhir teh hijau sebesar 4-6% per
total produk sehingga perlu dilakukan reduksi dengan metode plan-do-check-action
(PDCA) yang terdiri dari 8 langkah gugus kendali mutu (GKM) dan beberapa dari
7 alat bantu (check sheet, flowchart, histogram, diagram pareto, dan diagram
ishikawa).
Setelah diplotkan kedalam diagram ishikawa, diperoleh permasalaah utama
pada mesin, yaitu perbedaan design pelat antara penutup dan corong ball tea
sehingga dilakukan penyamaan desgin pelat antara penutup dan corong ball tea.
Penurunan persentase produk sweeping (off-grade) terhadap total produk yang
diperoleh setelah perbaikan sebesar 23%. Penurunan tersebut belum mencapai
target penurunan sweeping pabrik PT XYZ sebesar 30% dan persentase sweeping
pabrik lain sebesar 32% sehingga belum memuaskan. Hal ini disebabkan oleh
faktor dana dan waktu sehingga belum dapat dilakukan perbaikan lebih banyak. XYZ Ltd produces several quality levels of green tea : MT (whole leaf/peko ),
powder, bone, and sweeping (waste). The Off-grade products consist of powder,
bone, and sweeping. Sweeping is the highest type of off-grade product of 4-6% per
total product yield. This research were used the plan, do, check, and action (PDCA)
method which consists of 8 steps of the quality control circle (QCC) and some of
the seven tools (check sheet, flowchart, histogram, pareto chart, and ishikawa
chart).
After were being plotted on the Ishikawa diagram and the main problem with
the machine were gotten, the difference in plates were designed between the lid and
the ball tea funnels so the plates were designed to equalize between the cover and
the ball tea funnels. The decrease in the proportion of sweeping product (off-grade)
to the total product was obtained after improvement about 23%. This decrease had
not yet reached the target of reducing sweeping at PT XYZ's factory by 30% and
the proportion of sweeping at other factories by 32%, so it was unsatisfactory. This
was due to the factors of funds and time so that more improvements could not be
made.