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.