Penerapan Six Sigma DMAIC dalam Pengendalian Cacat Produk Pasta Tomyam Setelah Pengemasan di PT XYZ

Abstract

Penelitian ini bertujuan menerapkan metode Six Sigma dengan pendekatan DMAIC untuk mengendalikan cacat produk pasta tomyam setelah proses pengemasan di PT XYZ. Analisis dilakukan menggunakan CTQ, bagan kendali np, DPMO, level sigma, diagram Pareto, diagram sebab akibat, verifikasi penyebab, dan why-why analysis. Hasil penelitian menunjukkan bahwa dari total produksi 45.000 pcs diperoleh 1.899 produk cacat dengan persentase cacat 4,22%, nilai DPMO 14.066,67, dan level sigma 3,7. Cacat dominan adalah pinhole sebesar 59% dan seal tertekuk sebesar 31%. Akar penyebab meliputi belum adanya SOP pembersihan mesin seal, monitoring preventive maintenance yang belum optimal, belum adanya checklist pemeriksaan knife holder, serta belum ditetapkannya standar frekuensi pembersihan area sealing. Tindakan perbaikan meliputi penyusunan SOP pembersihan mesin seal, pembuatan jadwal dan checklist preventive maintenance, serta checklist pemeriksaan knife holder. Hasil perbaikan menurunkan persentase cacat menjadi 0,59%, DPMO menjadi 1.985,185, dan meningkatkan level sigma menjadi 4,3.

This study aims to apply the Six Sigma method using the DMAIC approach to control defects in tom yum paste products after the packaging process at PT XYZ. The analysis was conducted using CTQ, np-chart, DPMO, Sigma levels, Pareto charts, cause-and-effect diagrams, cause verification, and why-why analysis. The results of the study show that out of a total production of 45,000 units, 1,899 defective products were found, with a defect rate of 4.22%, a DPMO value of 14,066.67, and a sigma level of 3.7. The predominant defects were pinholes (59%) and bent seals (31%). The root causes include the lack of an SOP for cleaning the sealing machine, suboptimal monitoring of preventive maintenance, the absence of a knife holder inspection checklist, and the lack of established standards for the frequency of cleaning the sealing area. Corrective actions include developing an SOP for cleaning the sealing machine, creating a schedule and checklist for preventive maintenance, and establishing a knife holder inspection checklist. The improvements reduced the defect rate to 0.59%, the DPMO to 1,985.185, and increased the sigma level to 4.3.