Evaluasi Pengendalian Kualitas Bagian Pre-Delivery Inspection (PDI) Painting Metode DMAIC di PT XYZ

Abstract

PT XYZ adalah perusahaan manufaktur karoseri yang memproduksi unit bus, dimana penelitian ini fokus pada evaluasi pengendalian kualitas di bagian PDI Painting menggunakan metode DMAIC. Proses PDI Painting terdiri dari dua tahapan utama, yaitu Painting dan Clear, dengan hasil analisis menunjukkan bahwa proses Clear memiliki tingkat defect lebih tinggi, khususnya defect sagging pada lapisan clear. Tahap Measure meliputi perhitungan peta kendali, DPMO, dan diagram Pareto yang menguatkan bahwa kualitas proses Clear lebih buruk dibanding Painting. Melalui analisis fishbone dan perhitungan RPN dari analisis FMEA, ditemukan penyebab utama defect berupa kurangnya keahlian operator, tekanan angin kompresor yang rendah, kecepatan semprot yang tidak tepat, serta penggunaan material baru tanpa pengendalian risiko. Dengan metode 5 Why, akar masalah diidentifikasi dan solusi berupa pelatihan operator, preventive maintenance kompresor, sosialisasi instruksi kerja, dan prosedur pengendalian perubahan material diusulkan menggunakan pendekatan 5W1H. Tahap kontrol dilakukan dengan monitoring menggunakan OPL untuk memastikan keberlanjutan perbaikan, sehingga diharapkan mampu meningkatkan kualitas proses Clear dan menurunkan tingkat defect di PT XYZ.

PT XYZ is a manufacturing company specializing in bus body production. This study focuses on evaluating quality control in the PDI Painting section using the DMAIC method. The PDI Painting process consists of two main stages: Painting and Clear, with analysis results showing that the Clear process has a higher defect rate, particularly sagging defect on the clear coat layer. The Measure phase includes calculations of control charts, DPMO, and Pareto diagrams, which confirm that the quality of the Clear process is worse than Painting. Through fishbone analysis and RPN calculations from FMEA, the main causes of defects were identified as lack of operator skills, low compressor air pressure, incorrect spray speed, and the use of new materials without risk control. Using the 5 Why method, root causes were identified, and solutions such as operator training, preventive maintenance of compressors, work instruction socialization, and material change control procedures were proposed using the 5W1H approach. The Control phase was carried out with monitoring using One Point Lesson (OPL) to ensure the sustainability of improvements, which is expected to enhance the quality of the Clear process and reduce defect rates at PT XYZ.