USULAN RANCANGAN PERBAIKAN KUALITAS PEMELIHARAAN TABUNG GAS LPG 3 KG PADA PT SARANA GAS NUSARAYA DENGAN METODOLOGI SIX SIGMA

• Main Author: Abdan Syakuron, Muhammad
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/73615
• Institution: Institut Teknologi Bandung

PT Sarana Gas Nusaraya is a company that specializes in the repair and maintenance services of 3 kg LPG gas cylinders. In the year 2022, the company faced an average production demand shortfall of 2.17%. The primary reason for this was the occurrence of defective products. During the production process, PT Sarana Gas Nusaraya follows three main steps: retesting, repairing, and a combination of retesting and repairing. Out of these steps, 64% of the defects were found to originate from the combined retest and repair process. To address this issue, a research study was conducted to improve the quality of the retest and repair stage, with the goal of reducing the number of defects. The improvement process focused on the quality of the repair and maintenance procedures for 3 kg LPG gas cylinders, utilizing the Six Sigma methodology and the DMAIC (Define, Measure, Analyze, Improve, Control) approach. In the define stage, a project charter was created, and observations of the gas cylinder repair process were made. A SIPOC diagram was also developed to outline the process, identify the types of defects, and determine the Critical to Quality (CTQ) factors. In the measure stage, the percentage of seam defects from September 1 to October 31, 2022, was measured at 2.70%, with a sigma value of 2.8892. The analyze stage identified five main types of defects that were the focus of the research: uneven color coating, footring deformation, handguard deformation, color blending, and scratches on the cylinder. The factors and subfactors contributing to these defects were determined using the Delphi method and depicted in a cause-and-effect diagram. Additionally, the Failure Mode and Effects Analysis (FMEA) method helped identify five priority subfactors causing the problems that needed to be addressed. In the improve stage, several alternative solutions were proposed, but only four were approved by the company. These solutions included implementing a layout based on the 5S principles, using new trolleys designed to minimize defective products, employing a two-fingered fork handling approach with suitable specifications and design, and creating warning signs to indicate cylinder stacking limits on the floor and walls. During the control stage, a timeline for implementation was established to ensure the proper execution of all approved solutions. While these four solutions have been implemented, their implementation status is currently ongoing and not yet completed. In this research, there are ten factors and eleven sub-factors that cause defects. Five subfactors have been given alternative solutions and four alternative solutions have been formulated in this research.