Penerapan Six Sigma pada Pengendalian Produk Reject Cookies di PT XYZ Kabupaten Bogor

Abstract

PT XYZ merupakan produsen cookies di Indonesia yang menghadapi masalah produk reject. Penelitian ini bertujuan mengidentifikasi jenis reject terbanyak, faktor penyebab reject, memberikan usulan perbaikan, dan mengevaluasi efektivitas tindakan perbaikan. Metode Six Sigma dengan pendekatan DMAIC (Define, Measure, Analyze, Improve, Control) digunakan dalam analisis. Hasil penelitian menunjukkan jenis reject yang terjadi adalah patah, retak, rapuh dan gosong dengan reject patah sebagai yang tertinggi (81%). Berdasarkan analisis data diperoleh rata-rata DPMO sebesar 13.736,41 dan nilai sigma 3,72. Penyebab terjadinya reject berasal dari faktor manusia, metode, dan lingkungan. Usulan tindakan perbaikan yang dilakukan adalah penyusunan instruksi kerja (IK), pelatihan berkala, dan meningkatkan pengawasan selama proses produksi. Selain itu disarankan membuat area pendinginan semi tertutup serta menambahkan exhaust fan untuk membantu sirkulasi udara panas. Setelah dilakukan implementasi perbaikan diperoleh rata-rata nilai DPMO sebesar 5.953,13 dan nilai sigma 4,03. Nilai sigma ini mengalami peningkatan dari nilai sigma sebelumnya.

PT XYZ is a cookie manufacturer in Indonesia facing the problem of reject products. This study aims to identify the most common types of rejects, the factors causing them, and provide improvement suggestions. The Six Sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) approach was used in the analysis. The results showed that the types of rejects that occurred were broken, cracked, brittle, and burnt, with broken rejects being the highest (81%). Based on the data analysis, the average DPMO was 13736.41, the sigma level was 3.72. The causes of rejects came from human factors, methods, and the environment. The proposed improvement actions were the preparation of work instructions, regular training, and increased supervision during the production process. In addition, it is recommended to create a semi-closed cooling area, adding an exhaust fan to help circulate hot air. After implementing the improvements, the average DPMO value was 5.953,13 and the average sigma value was 4,03. This sigma value has increased from the previous sigma value.