Redesain Sistem HACCP Berbasis Analisis Proses dan Risiko Berdasarkan Kategori Proses Produksi di PT XYZ

Abstract

Sistem Hazard Analysis and Critical Control Point (HACCP) existing di PT XYZ tersebar dalam 11 dokumen yang mencakup 30 flow process, dikelompokkan berdasarkan merek, kategori produk, dan line produksi sehingga menimbulkan duplikasi dokumentasi, ketidaksesuaian antara tingkat resiko dan kategori pengendalian, serta lemahnya dukungan traceability. Penelitian ini bertujuan mengevaluasi kondisi sistem HACCP existing, menyusun redesain sistem HACCP berbasis analisis proses dan risiko berdasarkan kategori proses produksi, serta memvalidasi sistem hasil redesain sesuai kebutuhan operasional perusahaan. Penelitian menggunakan pendekatan Design Thingking dan Engineering Design Process yang terdiri atas tahapan eksplorasi, definisi masalah, ideasi, pengembangan prototipe, dan validasi. Pemilihan solusi pengelompokan HACCP dilakukan menggunakan metode Rank Order Centroid dan Simple Additive Weighting, menghasilkan solusi pengelompokan berdasarkan kategori proses produksi dengan nilai preferensi tertinggi. Hasil redesai menghasilkan lima kategori proses produksi dengan flow process dan hazard analysis yang lebih ringkas dan terintegrasi secara end-to-end, salah satu contohnya jumlah flow process kategori sandwich berkurang dari sembilan menjadi dua. Hasil validasi oleh tiga pakar melalui kuesioner dan wawancara menunjukan seluruh kriteria desain memperoleh kategori sangat baik (86,66%-100%), yang menunjukkan bahwa sistem HACCP hasil redesain layak diterapkan sebagai alat bantu pengelolaan keamanan pangan yang lebih efisien di PT XYZ.

The existing Hazard Analysis and Critical Control Point (HACCP) system at PT XYZ is spread across 11 documents covering 30 flow processes, grouped by brand, product category, and production line, resulting in duplicate documentation, mismatches between risk levels and control categories, and weak traceability support. This study aims to evaluate the condition of the existing HACCP system, compile a HACCP system redesign based on process and risk analysis based on production process categories, and validate the redesigned system according to the company's operational needs. The study uses the Design Thinking and Engineering Design Process approaches consisting of exploration, problem definition, ideation, prototype development, and validation stages. The selection of HACCP grouping solutions was carried out using the Rank Order Centroid and Simple Additive Weighting methods, resulting in grouping solutions based on production process categories with the highest preference values. The redesign results in five production process categories with more concise and end-to-end integrated flow processes and hazard analysis, for example, the number of sandwich category flow processes was reduced from nine to two. The validation results by three experts through questionnaires and interviews showed that all design criteria obtained a very good category (86.66%-100%), which indicates that the redesigned HACCP system is suitable for implementation as a more efficient food safety management tool at PT XYZ.