Penerapan Six sigma dalam Pengendalian Defect Double Cup Pada Produk Minuman Teh dengan Metode DMAIC di PT XYZ

Abstract

Minuman teh kemasan cup merupakan produk yang diminati masyarakat. PT XYZ memproduksi minuman teh ikemasan cup dan memiliki mesin baru yaitu mesin Line-7 yang masih menghasilkan kecacatan kemasan yang cukup tinggi. Penelitian ini bertujuan mengendalikan jenis dan faktor defect kemasan, dengan penerapan six sigma melalui metode define, measure, analyze, improve, dan control (DMAIC) dan memberikan rekomendasi perbaikan. Tahap define, ditemukan tiga jenis defect utama yaitu double cup, seal cup kurang press, dan seal cup meleleh. Tahap measure, nilai sigma sebelum perbaikan tercatat 5,57 dengan kategori rata-rata industri Jepang. Tahap analyze, defect dominan adalah double cup, yang disebabkan oleh faktor metode, material, manusia, dan mesin. Tahap improve, mencakup pembuatan instruksi kerja dan One Point Lesson penanganan cup, penambahan dan pelatihan karyawan harian lepas, pengawasan kedisiplinan oleh atasan langsung, sistem rotasi pekerja, modifikasi mesin fork feeder cup dan troli bahan kemasan, kunjungan ke supplier cup, serta pengaturan ulang ketinggian poka yoke. Setelah implementasi di tahap control, nilai sigma meningkat menjadi 5,80 dengan kategori rata-rata industri Jepang.

Cup-packaged tea is a beverage that is widely favored by consumers. PT XYZ produces cup-packaged tea and has recently operated a new machine, Line-7, which still produces a relatively high rate of packaging defects. This study aims to control defect types and causes using the Six Sigma method through the Define, Measure, Analyze, Improve, and Control (DMAIC) stages and provide improvement recommendations. In the Define phase, three main types of defects were identified, which include double cup, insufficiently pressed cup seal, and melted cup seal. The initial sigma level in the Measure phase was 5.57, classified as average in Japanese industry. The Analyze phase showed double cup as the dominant defect, caused by method, material, manpower, and machine factors. Improvements included creating Work Instruction and One Point Lesson for cup handling, adding and training temporary workers, enforcing discipline, rotating workers, modifying machines, visiting suppliers, and adjusting poka yoke height. The control phase the sigma level rose to 5.80, classified as average in Japanese industry.