Penerapan Siklus PDCA (Plan, Do, Check, Action) untuk Mengurangi Susut Bobot Produk Spicy Wing di PT XYZ

Abstract

PDCA (Plan, Do, Check, Action) adalah metode yang umum digunakan oleh perusahaan untuk mengidentifikasi permasalahan dan penyebabnya. Penelitian secara formal mengenai weight loss saat proses produksi dengan sampel yang besar dan proses berkesinambungan di industri pengolahan daging ayam spicy wing belum pernah dilakukan. Penelitian ini bertujuan mengkaji weight loss saat proses produksi, menganalisis faktor penyebab weight loss, dan membuat standard kombinasi proses yang paling optimal dalam produksi spicy wing di PT XYZ. Penelitian dilakukan dengan tahap Plan (identifikasi masalah, spesifikasi masalah, dan pengumpulan data), tahap Do (analisis data, pembuatan kesimpulan tentatif, dan pemeriksaan kesimpulan statistik), tahap Check (melakukan percobaan), dan tahap Action (melakukan tindakan perbaikan dan mempertahankan hasil perbaikan). Penentuan faktor penyebab weight loss dilakukan dengan metode PDCA dan dibantu dengan teknik GKM (Gugus Kendali Mutu) yang berisikan manajer, supervisor, dan leader pada masing-masing divisi. Hasil penelitian menunjukkan perlakuan pembekuan dengan Individual Quick Freezing (IQF) pada sampel middle wing dan wing stick dapat menurunkan thawing loss menjadi 0,68±0,19% dibandingkan perlakuan Blast Freezer (BF) dengan thawing loss sebesar 2,84±0,39%. Metode IQF ini juga menghasilkan saving cost sebesar Rp 1.195.200,-/Order Kerja Produksi (OKP). Kata kunci: freezing, GKM, PDCA, spicy wing, weight loss.

PDCA (Plan, Do, Check, Action) is a method commonly used in company to identify problems and it causes, to conduct the improving and controlling as well as to maintain the produced product quality. Formal the research topic about weight loss in production line with a large sample and continuous process in the chicken meat (spicy wing) processing industry has never been done. This research aimed to study weight loss in line production, to analyze the factors behind weight loss and create the most optimal process combination standard in the production of spicy wings at PT XYZ. The research was carried out with 4 stages. Plan (problem identification, problem specification and data collection), Do (data analysis, formulation of provisional conclusions and verification of statistical conclusions), Check (realization experiences), and Action (take corrective action and maintain improvement results). The determination of the factors that caused weight loss was done using PDCA method and supported by Quality Control Group (QCG) technique involving managers, supervisors, and leaders of each division. The results showed that freeze treatment with Individual Quick Freezing (IQF) on samples middle wing and wing stick was able to reduce thaw loss to 0.68±0.19% than the freez treatment with Blast Freezing (BF) with thaw loss 2.84±0.39%. IQF method was able to gain saving cost Rp 1.195.200,-/Production Work Order (PWO). Keywords: freezing, PDCA, spicy wing, QCG, weight loss.