Quality Plan Design Berbasis Metode SPC dan FMEA untuk Meminimalkan Reject Bentuk pada Base Popped Rice Cake di PT XYZ

Abstract

Reject bentuk pada produksi base popped rice cake di PT XYZ menyebabkan kehilangan hasil (yield loss) sehingga diperlukan sistem pengendalian mutu yang mampu mengendalikan proses secara lebih sistematis. Penelitian ini bertujuan menyusun rancangan Quality Plan dengan mengintegrasikan hasil analisis Statistical Process Control (SPC), Fishbone Diagram, Failure Mode and Effects Analysis (FMEA), dan hasil iterasi proses sebagai usulan pengendalian mutu untuk meminimalkan reject bentuk. Penelitian dilakukan melalui observasi lapangan, wawancara, pengumpulan data menggunakan check sheet, serta analisis menggunakan Diagram Pareto, P-chart, Fishbone Diagram, dan FMEA. Hasil penelitian menunjukkan bahwa reject Group D (tidak mengembang) merupakan penyumbang terbesar terhadap total reject, sedangkan FMEA mengidentifikasi kondisi pretreatment, suhu mesin, dan tekanan mesin sebagai prioritas pengendalian. Berdasarkan hasil tersebut disusun Quality Plan yang mengintegrasikan parameter proses, batas spesifikasi, metode pemantauan, frekuensi pemeriksaan, penanggung jawab, tindakan korektif, serta dokumen pendukung pada tahap pretreatment dan popping. Validasi oleh pihak manajerial PT XYZ menunjukkan tingkat kelayakan sebesar 100% dengan kategori sangat layak. Quality Plan yang dihasilkan diharapkan dapat menjadi pedoman pengendalian mutu untuk menjaga konsistensi proses produksi base popped rice cake di PT XYZ.

Shape defects in base popped rice cake production at PT XYZ result in yield loss, highlighting the need for a more systematic quality control system. This study aimed to develop a Quality Plan by integrating the results of Statistical Process Control (SPC), Fishbone Diagram, Failure Mode and Effects Analysis (FMEA), and process iteration as a proposed quality control approach to minimize shape defects. The research involved field observations, interviews, data collection using check sheets, and analyses employing the Pareto Diagram, P-chart, Fishbone Diagram, and FMEA. The results showed that Group D defects (unexpanded products) contributed the largest proportion of total rejects, while FMEA identified pretreatment conditions, machine temperature, and machine pressure as the priority process parameters requiring control. Based on these findings, a Quality Plan was developed comprising process control parameters, specification limits, monitoring methods, inspection frequency, responsible personnel, corrective actions, and supporting documents for the pretreatment and popping stages. Validation by PT XYZ management yielded a feasibility score of 100%, indicating that the proposed Quality Plan is highly feasible as a guideline for maintaining process consistency in base popped rice cake production at PT XYZ.