Penerapan Siklus Plan-Do-Check-Action untuk Mengurangi Cacat Permukaan pada Produk Outer Tube Model 2DP di PT. XYZ
DOI:
https://doi.org/10.32497/jrm.v20i1.6211Keywords:
8 langkah TPS, Cacat permukaan, Diagram Pareto, Lean manufacturing, Outer tube, PDCAAbstract
Tingkat cacat permukaan pada outer tube model 2DP di area pemesinan PT.XYZ masih mencapai 3,91%, melebihi Key Performance Indicator (KPI) perusahaan sebesar 1,36%. Kajian terdahulu membuktikan efektivitas siklus Plan-Do-Check-Action (PDCA) di berbagai sektor, namun belum ada penelitian empiris yang memfokuskan penurunan cacat permukaan komponen otomotif pada proses pemesinan di Indonesia dan mengukur dampak langsung integrasi PDCA terhadap pencapaian KPI serta penghematan biaya perbaikan. Oleh karena itu, penelitian ini bertujuan untuk menurunkan cacat permukaan outer tube model 2DP mencapai KPI sebesar 1,36% dan menghemat biaya pengerjaan ulang. Metode yang digunakan dengan mengkombinasikan 8 Langkah Toyota Production System (TPS), diagram Pareto, dan diagram ishikawa untuk mengidentifikasi akar penyebab dan menetapkan prioritas perbaikan. Dengan melakukan perbaikan meliputi, pemotongan dua-tahap (roughing-finishing), modifikasi program turning, penggantian diameter tool rib, dan penggunaan jig semi-cavity, hasil penelitian menunjukkan penurunan tingkat cacat permukaan pada produk outer tube model 2DP dari 3,91% menjadi 1,32% serta memberikan penghematan biaya tahunan perusahaan hingga Rp. 600.780.000. Kesimpulannya, integritas siklus PDCA menggunakan 8 langkah TPS dan alat bantu kualitas efektif dalam meningkatkan kualitas produk dan efisiensi biaya di industri Otomotif. Penelitian ini memperluas bukti empiris lean manufacturing di industri otomotif di Indonesia, menyediakan kerangka praktis perbaikan berbiaya rendah namun berdampak tinggi serta integrasi dengan teknologi industri 4.0.
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