Identifikasi Faktor Penyebab dan Strategi Pengendalian Food Loss akibat Cacat Fisik Mi dengan Pendekatan Six Sigma di PT XYZ

Abstract

Konsistensi mutu mi blok berdampak pada efisiensi produksi PT XYZ karena penolakan produk cacat memicu pemborosan material (food loss). Penelitian ini mengevaluasi kapabilitas proses, mengidentifikasi penyebab dominan, dan merumuskan strategi pengendalian menggunakan Six Sigma berkerangka Define, Measure, Analyze, Improve, dan Control (DMAIC). Kapabilitas proses terukur pada 4,11 Sigma dengan yield 98,64%. Meskipun kinerja tersebut tergolong baik, akumulasi pemborosan masih terjadi dengan dominasi kategori Hancur Halus (HH) dan Cacat Kotor (CK). Kategori HH dipicu prosedur clearing line yang menyisakan rontokan pada dead zone celah konveyor dan praktik penanganan kemacetan secara manual. Solusi yang diusulkan berupa modifikasi baffle plate = 45° dan penggunaan guide tool silikon. Sementara itu, kategori CK diakibatkan subjektivitas pengaturan parameter kecepatan mesin serta belum terstandarisasinya pelaksanaan prosedur pembersihan awal (flushing). Oleh karena itu, diusulkan penerapan indikator Visual Management RPM dan standarisasi toleransi startup. Keberlanjutan perbaikan dikendalikan melalui SOP, instruksi kerja, dan lembar pengawasan harian.

The quality consistency of noodle blocks significantly affects production efficiency at PT XYZ, as the rejection of defective products contributes to material loss (food loss). This study evaluates process capability, identifies dominant causes, and formulates control strategies using the Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC) framework. The process capability was measured at 4.11 Sigma with a yield of 98.64%. Despite this relatively good performance, material loss still occurred, predominantly in the Fine Crushed (HH) and Gross Defect (CK) categories. The HH category was associated with line-clearing procedures that left residue within conveyor dead zones, as well as manual product handling during conveyor jams. Proposed improvements included modifying the baffle plate to an inclination angle of = 45° and utilizing silicone guide tools. Meanwhile, the CK category was attributed to subjectivity in machine speed parameter settings and the lack of standardized flushing procedures. Therefore, the implementation of RPM Visual Management indicators and the standardization of startup tolerances were proposed. The sustainability of the improvements is controlled through SOPs, work instructions, and daily monitoring sheets.