Minimalisasi waste pada proses produksi FTDJ-12 dengan pendekatan lean six sigma di stamping factory PT Mitsubishi Krama Yudha Motors and Manufacturing

Maryana, Widya Nurcahayanty and Perdana, Mochamad Putra (2024) Minimalisasi waste pada proses produksi FTDJ-12 dengan pendekatan lean six sigma di stamping factory PT Mitsubishi Krama Yudha Motors and Manufacturing. Project Report. Fakultas Sains dan Teknologi UAI, Jakarta. (Unpublished)

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Abstract

PT Mitsubishi Krama Yudha Motors & Manufacturing Stamping Factory is a manufacturing company that produces FTDJ-12. The current production process of FTDJ-12 is through section stamping, welding B, and welding I, with an overall defect rate of 1.47% and a sigma level of 3.96, even though the company targets a defect rate of 0% and a sigma level of 4.5. For this reason, this study uses a lean six sigma approach with 4 stages, including defining, measuring, analysing, and improving to reduce waste and pursue company targets. The study found that the critical section affects the overall defect rate, and the sigma level is stamping, with a defect rate of 4.47% and a sigma level of 2.95. The waste primarily causes low productivity in section stamping, and the drawing process resulting in scratched parts is the main issue. This problem causes a lost product opportunity of 9,184 units, or 46.33% of the total goods produced by the stamping section. Furthermore, root cause analysis was carried out to find the root cause of the problem. The three root causes causing the problem are the non-implementation of quality control procedures, the perforated die, and the lack of documentation for using a die. Therefore, three improvements are proposed: the making of Stamping Process & Inspection SOP, procurement of SKD die with coating, and the application of preventive maintenance. If these improvements are implemented, it is targeted to reduce the defect rate to 0.01% and increase the sigma level to 4.38.

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