ANALISIS PRODUKSI SPAREPART OTOMOTIF PADA PERUSAHAAN XYZ MENGGUNAKAN METODE SEVEN TOOLS DAN SIX SIGMA

Abstract

ABSTRAK: Penelitian ini membahas pengendalian kualitas produksi sparepart otomotif pada Perusahaan XYZ menggunakan metode Seven Tools dan Six Sigma. Perusahaan mengalami kerugian signifikan akibat cacat produksi yang melampaui standar perusahaan, yang ditetapkan sebesar 5% per bulan. Melalui analisis yang mendalam menggunakan Seven Tools dan Six Sigma, ditemukan bahwa perbaikan diperlukan pada beberapa aspek utama, yaitu sumber daya manusia (SDM), mesin, metode, dan material. Implementasi perbaikan yang tepat diharapkan dapat mengurangi tingkat kecacatan produk dan meningkatkan efisiensi produksi secara keseluruhan. Dalam penelitian ini, digunakan metode campuran yang mencakup pendekatan kualitatif dan kuantitatif. Langkah-langkah yang ditempuh meliputi perumusan masalah, studi literatur, serta pengumpulan data melalui observasi, sesi brainstorming, dan wawancara. Seven Tools dan Six Sigma digunakan dalam mengolah data yang telah dikumpulkan. Hasil analisis menunjukkan bahwa intensitas operasi mesin yang tinggi dan penggunaan mesin lama menjadi salah satu penyebab utama cacat produksi. Oleh karena itu, pengecekan rutin dan penggantian mesin yang sudah mencapai batas maksimal penggunaan sangat diperlukan. Selain itu, pelatihan khusus kepada karyawan mengenai perawatan mesin juga menjadi salah satu rekomendasi penting untuk meningkatkan kualitas produksi. Nilai rata-rata DPMO sebesar 27.777,78 dan nilai sigma sebesar 3,415 menunjukkan bahwa kualitas pengendalian proses di perusahaan ini cukup baik, berdasarkan perhitungan Defect Per Million Opportunities (DPMO) dan nilai Sigma. Namun, masih terdapat cacat produksi yang melewati batas pengendalian, sehingga perlu dicari penyebabnya dan dilakukan perbaikan lebih lanjut. Penelitian ini menunjukkan bahwa pendekatan sistematis dalam pengendalian kualitas, seperti yang ditawarkan oleh Seven Tools dan Six Sigma, dapat memberikan hasil yang signifikan dalam meningkatkan kualitas dan efisiensi produksi di industri otomotif.

ABSTRACT: This research discusses the quality control of automotive spare parts production at XYZ Company using the Seven Tools and Six Sigma methods. The company suffered significant losses due to production defects that exceeded the company standard, which was set at 5% per month. Through in-depth analysis using Seven Tools and Six Sigma, it was found that improvements were needed in several key aspects, namely human resources (HR), machines, methods, and materials. Proper implementation of improvements is expected to reduce the product defect rate and increase overall production efficiency. In this research, a mixed method was used that included both qualitative and quantitative approaches. The steps taken include problem formulation, literature study, and data collection through observation, brainstorming sessions, and interviews. Seven Tools and Six Sigma were used in processing the data collected. The results of the analysis showed that the high intensity of machine operations and the use of old machines were among the main causes of production defects. Therefore, routine checks and replacement of machines that have reached the maximum limit of use are needed. In addition, special training for employees regarding machine maintenance is also one of the important recommendations to improve production quality. The average DPMO value of 27,777.78 and the sigma value of 3.415 indicate that the quality of process control in this company is quite good, based on the calculation of Defect Per Million Opportunities (DPMO) and Sigma value. However, there are still production defects that cross the control limit, so it is necessary to find the cause and make further improvements. This research shows that systematic approaches to quality control, such as those offered by the Seven Tools and Six Sigma, can provide significant results in improving quality and production efficiency in the automotive industry.