PENGENDALIAN KUALITAS PADA PRODUK HIGH GRADE COREBOARD DENGAN METODE SIX SIGMA DAN FAILURE MODE AND EFFECT ANALYSIS (studi kasus di PT Papertech Indonesia, Subang)

NOEGROHO, NOVANDA SATRIA (2025) PENGENDALIAN KUALITAS PADA PRODUK HIGH GRADE COREBOARD DENGAN METODE SIX SIGMA DAN FAILURE MODE AND EFFECT ANALYSIS (studi kasus di PT Papertech Indonesia, Subang). Skripsi thesis, UPN Veteran Yogyakarta.

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Abstract

ABSTRAK
PT Papertech Indonesia, perusahaan yang bergerak di industri pulp dan
kertas dengan produk utama berupa kertas karton tipe chipboard dan coreboard,
menghadapi tantangan dalam menjaga kualitas produksi di tengah persaingan
global yang ketat. Perusahaan menerapkan strategi Make to Order (MTO) dan
menetapkan standar kualitas tinggi untuk produknya, dengan harapan mencapai
zero defect dalam setiap produksi. Namun, data menunjukkan masih adanya produk
cacat atau defect pada produksi high grade coreboard, yang mencapai 4% dari total
produksi bulanan. Penelitian dilakukan dengan menggunakan data hasil produksi
dan kecacatan pada bulan januari tahun 2024, dengan fokus pada peningkatan
pengendalian kualitas di setiap tahap proses produksi.
Penelitian ini bertujuan untuk memberikan usulan guna pengurangan
angka defect tersebut melalui pendekatan metodologi Six Sigma DMAIC (Define,
Measure, Analyze, Improve, Control) serta analisis FMEA (Failure Mode and Effect
Analysis) untuk mengidentifikasi penyebab kecacatan dan merumuskan solusi
perbaikan. Metode Six Sigma DMAIC digunakan untuk mengurangi jumlah cacat
secara sistematis, sementara FMEA membantu menganalisis potensi kegagalan dan
dampaknya pada kualitas produk.
Dari hasil penelitian bahwa jenis cacat yang memiliki RPN di atas 300
perlu dilakukan perbaikan, yang dimana jenis cacat tersebut adalah cacat caliper,
cacat GSM, overlapping dan cacat moist. Usulan perbaikan yang diberikan adalah
melakukan peningkatan pada Press section dengan menerapkan teknologi
controlled nip loading, pengimplementasian sistem kontrol otomatis berbasis
closed loop yang mengintegrasikan sensor aliran dan konsistensi stock dengan
pengatur kecepatan wire, pemasangan dancer roll sebagai zona akumulator, dan
penerapan sistem zonasi suhu pada dryer. Usulan perbaikan yang telah diusulkan,
selanjutnya dilakukan critical review guna mengevaluasi kelayakan teknis,
ekonomis, dan operasional dari setiap usulan perbaikan yang diberikan berdasarkan
data, teori dan literatur yang relevan berupa jurnal terdahulu yang telah melakukan
implementasi terhadap usulan yang diberikan.
Kata Kunci : Pengendalian Kualitas, Six Sigma DMAIC, FMEA, Zero Defect,
High Grade Coreboard.
x
ABSTRACT
PT Papertech Indonesia, a company engaged in the pulp and paper
industry with main products of chipboard and coreboard cardboard, faces
challenges in maintaining production quality amidst intense global competition.
The company implements a Make to Order (MTO) strategy and sets high-quality
standards for its products, aiming to achieve zero defect in every production run.
However, data indicates that defective or non-conforming products still occur in the
production of high-grade coreboard, reaching up to 4% of total monthly production.
This research was conducted using production and defect data from January 2024,
focusing on improving quality control at each stage of the production process.
The study aims to propose solutions for reducing the defect rate through
the application of the Six Sigma DMAIC (Define, Measure, Analyze, Improve,
Control) methodology and FMEA (Failure Mode and Effect Analysis) to identify
root causes of defects and formulate corrective actions. The Six Sigma DMAIC
method is used to systematically reduce the number of defects, while FMEA assists
in analyzing potential failures and their impact on product quality.
Based on the research results, defect types with an RPN value above 300
require corrective actions. These defect types include caliper defects, GSM defects,
overlapping, and moisture defects. The proposed improvements include enhancing
the press section by implementing controlled nip loading technology, applying a
closed-loop automatic control system that integrates flow and stock consistency
sensors with wire speed regulation, installing a dancer roll as an accumulator zone,
and implementing a temperature zoning system in the dryer. These proposed
improvements are then subjected to a critical review to evaluate their technical,
economic, and operational feasibility, based on relevant data, theories, and
literature,
including previous journals that have implemented similar
improvements.
Keywords : Quality Control, Six Sigma DMAIC, FMEA, Zero Defect, High Grade
Coreboard.
xi

Item Type: Tugas Akhir (Skripsi)
Uncontrolled Keywords: Pengendalian Kualitas, Six Sigma DMAIC, FMEA, Zero Defect, High Grade Coreboard.
Subjek: H Social Sciences > HD Industries. Land use. Labor
Divisions: Fakultas Teknik Industri > (S1) Teknik Industri
Depositing User: Eko Yuli
Date Deposited: 17 Oct 2025 02:34
Last Modified: 17 Oct 2025 02:34
URI: http://eprints.upnyk.ac.id/id/eprint/44520

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