Jurnal Sains dan Aplikasi Keilmuan Teknik Industri (SAKTI)

Analysis of Pipe Water Inlet EW010 Quality Control Using Six Sigma and Failure Mode and Effect Analysis

Faris Fadhlullah — 2024-06-28

PT Wijaya Karya Industri dan Konstruksi has businesses in the fields of Steel, Plastic, Pressing and Casting (PPC) Manufacturing and heavy construction equipment. The PPC factory produces various kinds of manufacturing components, one of which is vehicle spare parts made from metal which are produced using a casting process. One of the products produced using a casting process is Pipe Water Inlet EW010. There are many Pipes Water Inlet EW010 defective products with an average of 52% defective products in July-August 2023. The research was conducted to analyze the sigma value and determine the factors of product defects and the impact of the defects to provide suggestions for product quality improvement. In this research, the method applied is the Six Sigma method and FMEA, by implementing DMAIC (Define, Measure, Analyze, and Control). From this research, the results showed that the most common defects were Leaking, Pen/core, and Porous, namely 89% cumulative. Pipe Water Inlet EW010 products are currently at level 2.44 sigma so corrective action needs to be taken to reach the six-sigma level. By applying the FMEA method, it can be seen that the most significant and most frequently occurring product defects are caused by poor core quality and work method errors. Therefore, the recommended alternative repair solution is to improve the quality of the cores used and improve work methods. The results show an increase in the sigma level value from 2.44 to 2.86 and a decrease in average defects from 52% to 23%.

Defect Analysis Using Failure Mode and Effects Analysis and Fault Tree Analysis

Elvina Pramono — 2024-06-07

Quality control is a vital aspect of product manufacturing, ensuring adherence to predefined standards and meeting consumer expectations. This study focuses on quality control within the cigarette production process, specifically in PT PID Ongkowidjojo, a prominent manufacturer located in Malang, Indonesia. Despite meticulous production processes, defects in cigarette sticks persist, leading to waste of resources, time, and potential degradation in product quality. The research employs Failure Mode and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) to identify, analyze, and propose solutions for defects occurring in the maker machine division. Initial analysis reveals common defects such as glue inadequacy, tears in wrappers, and tobacco density inconsistencies, prompting the need for systematic improvements. Through FMEA and FTA methodologies, root causes of defects are pinpointed, and corrective actions are proposed. Implementation of these measures results in a reduction of Risk Priority Number (RPN) values for major defects, indicating a positive impact on production quality. However, limitations in utilizing gate symbols within FTA are acknowledged, suggesting avenues for future research to optimize analytical techniques. This study contributes to the ongoing discourse on quality control in manufacturing industries, particularly in addressing common defects in cigarette production. By integrating FMEA and FTA methodologies, it offers insights into effective defect mitigation strategies, highlighting the importance of continuous improvement in maintaining product quality and operational efficiency.

Analisis Efektivitas Mesin Cetak Flexo menggunakan Metode Overall Equipment Effectiveness Berbasis Six Big Losses

Angelica Audrey Saw Shu Zhen — 2024-06-28

PT X is a manufacturing company operating in the integrated cardboard industry, utilizing various machines, including flexography machines. This study aims to analyze the primary causes of production deficiencies in the flexography process and provide improvement recommendations using the Six Big Losses-based Overall Equipment Effectiveness (OEE) method. The OEE analysis revealed that the average availability ratio is 88.8%, falling short of the world-class standard of 90%. A deeper analysis using the Six Big Losses methodology identified that the primary cause for not achieving the desired availability ratio is the high percentage of setup and adjustment losses, which stands at 7%. To address these issues, several recommendations are proposed. Firstly, conducting comprehensive training for operators on the proper and correct operation of flexography machines is essential. This training will enhance their technical skills and reduce the time lost during setup and adjustments. Secondly, implementing daily briefings for operators before shifts begin, coupled with regular supervision, will ensure consistent adherence to operational standards. Moreover, establishing a routine and time-limited cleaning schedule for machines and work locations will minimize unexpected downtimes due to maintenance issues. Finally, developing and enforcing standardized machine operation protocols will promote discipline among operators, ensuring that all procedures are followed meticulously. These recommendations aim to improve the overall efficiency of flexography machines, thereby increasing the availability ratio to meet or exceed the world-class standard. By addressing the root causes of production inefficiencies, PT X can enhance its operational performance and maintain its competitive edge in the cardboard industry.

Usability Test Using the System Usability Scale in the Industrial Engineering Laboratory Universitas X Indonesia

Saiful Rowi — 2024-06-28

In a quality education system, services are integral to delivering quality education. Providing excellent, effective, and efficient services to students is crucial for their success at the university, including laboratory services to support student practicum. However, the laboratory services in the Industrial Engineering Program Study at Universitas X in Indonesia seem to fall short of expectations and do not fully meet student needs. This study aims to assess the usability of the Industrial Engineering Laboratory services at Universitas X. The System Usability Scale (SUS) method is employed to gauge the service scale's effectiveness. The SUS score obtained in this study is 53, indicating that the services at the Industrial Engineering Laboratory Universitas X are categorized as acceptable but require improvement. Therefore, while the system created is deemed acceptable by its users, it needs enhancement to positively impact Industrial Engineering laboratory services.

Cycle Time Study in Improving Production Output in the Garment Industry Sewing Line

Mayesti Kurnianingtias — 2024-06-27

The garment industry is one of the fastest-paced production environments, where speed and accuracy are crucial for meeting global customer demand. Cycle time plays an important role in satisfying the speed factor as it represents the overall time needed to produce a single piece of a product. Maintaining an appropriate cycle time is key to achieving production line balance. This study aims to analyze the cycle time of men's jacket production on a sewing line in an Indonesian garment industry by comparing the actual cycle time with the standard cycle time based on the operation breakdown for each production process step. Four significant discrepancies in actual cycle time were identified, ranging from 16% to 95%, indicating that the actual cycle time was significantly longer than the standard cycle time. The root cause of the highest cycle time was analyzed using Fishbone and 5 Whys analysis to understand the problem from each factor and sub-factor. Six improvement action plans were proposed and implemented, resulting in a 57.81% reduction in actual cycle time, from 127.66 seconds to 53.85 seconds, making it 17.66% faster than the standard cycle time. Furthermore, the total output per hour increased by approximately 216.67%, from 12 pieces to 38 pieces. This result implies that the study successfully identified the root of the problem on the sewing line and managed to increase production output.

Determination of Physical Enviroment Factor Levels to Improve Productivity in the Filleting Process

Johan Chenwidy — 2024-06-29

PT Bumi Menara Internusa Surabaya is a producer of processed frozen seafood products, which uses a lot of human resources in its production. The use of human resources in the production process is closely related to productivity which will ultimately affect work efficiency and effectiveness. PT Bumi Menara Internusa itself has many products from various types of fish, one of which is salmon. The production process for frozen salmon products has several processing stages, one of which is the filleting process. The filleting process is a process where the fish flesh is separated from the fish backbone. To determine employee productivity in the production of frozen salmon products, employee output will be recorded every hour. Based on observations, records held by the company and interviews that have been conducted, it was found that employees in the fillet section were often unable to achieve the daily output targets that had been planned and calculated by the department concerned. Therefore, research was carried out using the Taguchi method to increase the productivity of salmon fillet employees. The results of the research carried out were an increase in productivity value of 3.556.