PERBAIKAN PROSES PRODUKSI UNTUK MENGURANGI CACAT PRODUK DISC ROTOR MODEL 650A DI-LINE DR11 PT XYZ

DAFFA ARYA PRADANA, . (2025) PERBAIKAN PROSES PRODUKSI UNTUK MENGURANGI CACAT PRODUK DISC ROTOR MODEL 650A DI-LINE DR11 PT XYZ. Sarjana thesis, UNIVERSITAS NEGERI JAKARTA.

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Abstract

Tingginya tingkat cacat pada proses produksi disc rotor model 650A di-line DR11 PT XYZ sebesar 0,70% yang melebihi batas toleransi perusahaan sebesar 0,15% menunjukkan adanya permasalahan kualitas yang perlu dianalisis secara sistematis. Jenis cacat dominan adalah Diameter 108 yang menyebabkan ketidaksesuaian dimensi hasil machining terhadap standar spesifikasi. Penelitian ini bertujuan untuk mengidentifikasi akar penyebab cacat dan menerapkan langkah perbaikan guna menurunkan tingkat kecacatan menggunakan metode 8 Langkah Sistem Produksi Toyota (Toyota Production System) yang di kombinasikan dengan Seven Quality Control Tools (7 QC Tools). Metode penelitian dilakukan melalui observasi langsung di area kerja, pengumpulan data cacat produksi periode Mei-Juli 2025, serta analisis menggunakan diagram Pareto, dan diagram sebab-akibat (fishbone). Hasil penelitian menunjukkan bahwa faktor mesin menjadi penyebab utama cacat, meliputi tidak adanya cover pada slide Z-axis, posisi tool post tidak center (miring 0,4 mm), dan sistem autoblow hanya terdapat di satu sisi chuck. Setelah dilakukan tindakan perbaikan melalui pemasangan cover, penyetelan ulang tool post, dan penambahan autoblow, tingkat cacat Diameter 108 menurun dari 31 pcs menjadi 0 pcs (0%). Kesimpulan penelitian ini menunjukkan bahwa penerapan 8 Langkah Sistem Produksi Toyota terbukti efektif dalam menghilangkan akar penyebab cacat, meningkatkan stabilitas proses, serta sehingga mendukung tercapainya kondisi zero defect di lini produksi.*****The high defect rate in the production process of disc rotor model 650A on line DR11 at PT XYZ, reaching 0.70% and exceeding the company’s tolerance limit of 0.15%, indicates a quality issue that needs to be analyzed systematically. The dominant defect type is Diameter 108, which causes dimensional deviations in the machining results. This study aims to identify the root causes of defects and implement corrective actions to reduce the defect rate using the 8 Steps of the Toyota Production System (TPS) combined with the Seven Quality Control Tools (7 QC Tools). The research was conducted through direct observation in the production area, collection of defect data from May to July 2025, and analysis using the Pareto diagram, and fishbone diagram. The results showed that the machine factor was the main cause of the defect, including the absence of a Z-axis slide cover, an off-center tool post (tilted 0.4 mm), and an air blow system installed only on one side of the chuck. After corrective actions such as installing a slide cover, realigning the tool post, and adding an air blow system, the Diameter 108 defect decreased from 31 pcs to 0 pcs (0%). The study concludes that the application of the 8 Steps of the Toyota Production System effectively eliminates root causes of defects, enhances process stability, and achieving a zero-defect condition in the production line.

Item Type:	Thesis (Sarjana)
Additional Information:	1). Dr. Wardoyo, M.T. 2). Dr. Siska Titik Dwiyati, M.T.
Subjects:	Teknologi dan Ilmu Terapan > Manufaktur
Divisions:	FT > D IV Teknologi Rekayasa Manufaktur
Depositing User:	Users 31740 not found.
Date Deposited:	18 Nov 2025 02:46
Last Modified:	18 Nov 2025 02:46
URI:	http://repository.unj.ac.id/id/eprint/62813

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