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Lampiran 1. Gambar Defect

Defect Under Cure

Defect Leaky Bladder

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Lampiran 2. Data Jumlah Produksi Katagori LT Tahun 2010-2015

Lampiran 3 Data Jumlah Produksi Ban Katagori DB Tahun 2010-2015 KATAGORI LT BULAN TAHUN 2010 2011 2012 2013 2014 2015 JANUARI 225,572 195,890 165,322 191,430 165,253 174,834 FEBRUARI 207,158 185,883 163,682 182,956 171,463 154,563 MARET 225,572 195,080 186,955 205,866 214,587 140,224 APRIL 223,620 172,764 174,660 211,631 208,842 133,466 MEI 231,782 169,702 171,322 225,287 179,881 144,960 JUNI 200,690 190,416 169,410 223,806 155,282 202,993 JULI 226,572 199,400 174,192 238,435 132,986 142,439 AGUSTUS 212,305 151,361 119,577 140,412 152,568 198,159 SEPTEMBER 130,957 135,362 176,000 210,198 201,212 171,513 OKTOBER 217,311 173,963 179,172 219,037 203,423 186,079 NOVEMBER 198,729 148,719 184,832 205,868 183,351 186,653 DESEMEBER 200,993 153,477 188,498 179,517 166,048 137,270 TOTAL 2,501,261 2,072,017 2,053,622 2,434,443 2,134,896 1,973,153 GRAND TOTAL 13,169,392 KATAGORI DB BULAN TAHUN 2010 2011 2012 2013 2014 2015 JANUARI 100,716 114,378 118,568 136,349 111,317 118,720 FEBRUARI 94,435 108,338 113,776 124,895 96,392 86,843 MARET 100,746 120,057 125,256 145,952 105,572 23,888 APRIL 98,811 100,922 123,144 139,503 100,044 72,415 MEI 102,561 77,206 124,199 140,114 104,927 93,550 JUNI 92,497 99,986 118,526 122,826 102,518 75,619 JULI 101,555 114,671 121,273 123,634 87,298 61,538 AGUSTUS 102,747 91,046 79,863 75,766 102,231 100,714 SEPTEMBER 67,154 92,046 123,667 106,382 124,005 100,423 OKTOBER 105,326 117,044 133,725 117,582 102,307 108,290 NOVEMBER 96,035 109,072 130,946 123,400 107,949 117,091 DESEMEBER 106,877 114,982 131,815 110,859 114,872 118,123 TOTAL 1,169,460 1,259,748 1,444,758 1,467,262 1,259,432 1,077,214 GRAND TOTAL _6,600,660

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Lampiran 4. Data Jumlah Produksi Ban Katagori TB Tahun 2010-2015

Lampiran 5. Data Jumlah Defect Ban Katagori Ban LT Tahun 2010-2015 KATAGORI TB BULAN TAHUN 2010 2011 2012 2013 2014 2015 JANUARI 62,923 60,225 64,280 59,092 61,672 50,085 FEBRUARI 62,319 57,428 63,325 52,934 55,044 42,196 MARET 62,923 59,749 70,335 61,014 60,186 26,175 APRIL 56,921 48,548 68,539 55,440 46,076 24,995 MEI 54,965 37,555 68,433 57,985 40,120 37,960 JUNI 46,985 41,649 66,648 51,232 45,729 48,388 JULI 51,034 49,900 67,595 51,692 39,775 33,707 AGUSTUS 48,240 49,082 43,646 32,986 43,014 47,028 SEPTEMBER 33,282 49,326 67,069 53,191 53,739 43,114 OKTOBER 54,514 64,772 67,441 59,514 52,348 49,349 NOVEMBER 53,758 57,159 67,719 64,223 44,593 46,771 DESEMEBER 57,961 59,351 67,938 61,721 50,432 36,250 TOTAL 645,825 634,744 782,968 661,024 592,728 486,018 GRAND TOTAL _3,803,307 BULAN KATAGORI LT TAHUN 2010 2011 2012 2013 2014 2015 JANUARI 326 234 170 214 157 167 FEBRUARI 336 176 214 202 184 172 MARET 256 328 180 316 253 166 APRIL 279 208 161 237 298 181 MEI 283 319 159 342 279 130 JUNI 462 377 129 279 280 183 JULI 282 359 149 258 204 161 AGUSTUS 298 267 151 220 265 179 SEPTEMBER 182 229 177 323 225 205 OKTOBER 310 300 157 260 203 200 NOVEMBER 341 161 189 205 169 192 DESEMEBER 280 151 166 182 206 165 TOTAL 3,635 3,109 2,002 3,038 2,723 2,101 GRAND TOTAL 14,507

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Lampiran 6. Data Defect Semua Ban Katagori LT Tahun 2010-2015 NO DEFECT DEFE CT CODE 2010 2011 2012 2013 2014 2015 TOTAL 1 Air Blister AB 3 3 1 0 0 2 9 3 Bead Bare BB 94 50 41 44 20 18 267 4 Bead Transfer BT 3 7 5 7 2 0 24 5 Bladder Cacat BLDC 0 0 0 0 0 0 0 10 Buckle Bladder BBL 86 93 101 211 226 108 825 11 Center Buckle CBL 2 14 4 5 26 8 59 15 Crown Bare CB 0 1 0 0 2 2 5 16 Damage DG 126 92 99 308 139 77 841 17 Damage Bladder DBL 1 6 12 3 15 3 40 18 Dirty Mold DM 7 0 1 1 2 4 15 19 Double Brand DBR 10 0 0 0 0 2 12 20 Double Tyre DBT 0 4 0 4 0 0 8 24 Foreign Material FM 93 108 105 132 106 75 619 25 FM Flow FMF 0 0 3 9 0 0 12 26 FM Others FMO 0 0 0 0 0 0 0 27 Inner Paste IP 65 311 57 175 174 62 844 28 Kinked Bead KB 94 115 70 222 189 211 901 29 Leaky Bladder LB 519 307 298 332 312 140 1908 31 No Serial NS 0 0 0 0 1 0 1 33 Open Mold OM 31 30 20 28 47 26 182

36 Over Cure OVC 197 146 66 83 107 98 697

37 Side Bare SB 1 0 2 0 0 1 4

38 Under Cure UC 755 606 415 677 645 597 3695 39 Under Cure Bead UCB 416 350 203 303 257 245 1774 40 Under Cure Interior UCI 371 224 133 126 119 89 1062

41 Under PCI PCI 29 38 26 37 35 44 209

42 Wrong Cover Plate WCP 0 0 0 0 0 0 0

43 Wrong Green Tyre WGT 15 15 4 5 4 2 45

44 Wrong Ply WP 0 0 0 0 0 0 0

45 Wrong Marking WM 0 0 0 0 0 0 0

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Lampiran

7. Data Defect Dari Proses Curing Katagoeri LT 2010-2015

NO DEFECT DEFECT

CODE 2010 2011 2012 2013 2014 2015 TOTAL

1 Under Cure UC 755 606 415 677 645 597 3695

2 Leaky Bladder LB 519 307 298 332 312 140 1908 3 Under Cure Bead UCB 416 350 203 303 257 245 1774 4 Under Cure Interior UCI 371 224 133 126 119 89 1062 5 Inner Paste IP 65 311 57 175 174 62 844 6 Damage DG 126 92 99 308 139 77 841 7 Buckle Bladder BBL 86 93 101 211 226 108 825 8 Kinked Bead KB 94 115 70 222 189 211 901

9 Over Cure OVC 197 146 66 83 107 98 697

10 Foreign Material FM 93 108 105 132 106 75 619

11 Bead Bare BB 94 50 41 44 20 18 267

12 Under PCI PCI 29 38 26 37 35 44 209

13 Open Mold OM 31 30 20 28 47 26 182

14 Center Buckle CBL 2 14 4 5 26 8 59

15 Wrong Green Tyre WGT 15 15 4 5 4 2 45

16 Damage Bladder DBL 1 6 12 3 15 3 40 17 Bead Transfer BT 3 7 5 7 2 0 24 18 FM Flow FMF 0 0 3 9 0 0 12 19 Dirty Mold DM 7 0 1 1 2 4 15 20 Double Brand DBR 10 0 0 0 0 2 12 21 Double Tyre DBT 0 4 0 4 0 0 8 22 Air Blister AB 3 3 1 0 0 2 9 23 Crown Bare CB 0 1 0 0 2 2 5 24 Side Bare SB 1 0 2 0 0 1 4 25 No Serial NS 0 0 0 0 1 0 1 26 Bladder Cacat BLDC 0 0 0 0 0 0 0 27 FM Others FMO 0 0 0 0 0 0 0

28 Wrong Cover Plate WCP 0 0 0 0 0 0 0

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Lampiran 8. Data 3 CTQ Ban Katagori LT Tahun 2010-2015

NO. BULAN UC LB UCB TOTAL _PRODUKSIJUMLAH

1 JANUARI 2010 31 48 44 123 225,572 2 FEBRUARI 2010 69 58 53 180 207,158 3 MARET 2010 33 71 31 135 225,572 4 APRIL 2010 83 39 33 155 223,620 5 MEI 2010 51 44 21 116 231,782 6 JUNI 2010 91 31 15 137 200,690 7 JULI 2010 67 40 46 153 226,572 8 AGUSTUS 2010 74 51 36 161 212,305 9 SEPTEMBER 2010 53 24 8 85 130,957 10 OKTOBER 2010 62 44 58 164 217,311 11 NOVENBER 2010 77 39 38 154 198,729 12 DESEMBER 2010 64 30 33 127 200,993 13 JANUARI 2011 55 18 52 125 195,890 14 FEBRUARI 2011 27 25 19 71 185,883 15 MARET 2011 70 47 45 162 195,080 16 APRIL 2011 41 26 15 82 172,764 17 MEI 2011 62 30 40 132 169,702 18 JUNI 2011 90 27 27 144 190,416 19 JULI 2011 60 25 30 115 199,400 20 AGUSTUS 2011 72 38 26 136 151,361 21 SEPTEMBER 2011 30 34 30 94 135,362 22 OKTOBER 2011 39 15 30 84 173,963 23 NOVENBER 2011 39 12 11 62 148,719 24 DESEMBER 2011 21 10 25 56 153,477 25 JANUARI 2012 36 19 22 77 165,322 26 FEBRUARI 2012 40 37 30 107 163,682 27 MARET 2012 52 21 13 86 186,955 28 APRIL 2012 32 12 16 60 174,660 29 MEI 2012 37 25 23 85 171,322 30 JUNI 2012 30 25 11 66 169,410 31 JULI 2012 22 25 26 73 174,192 32 AGUSTUS 2012 28 20 13 61 119,577 33 SEPTEMBER 2012 42 42 18 102 176,000 34 OKTOBER 2012 30 21 9 60 179,172 35 NOVENBER 2012 33 25 18 76 184,832 36 DESEMBER 2012 33 26 4 63 188,498

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Lampiran 9. Data 3 CTQ Ban Katagori LT Tahun 2010-2015 (lanjutan)

NO. BULAN UC LB UCB TOTAL _PRODUKSIJUMLAH

37 JANUARI 2013 42 31 6 79 191,430 38 FEBRUARI 2013 42 26 20 88 182,956 39 MARET 2013 61 34 55 150 205,866 40 APRIL 2013 64 31 33 128 211,631 41 MEI 2013 73 35 41 149 225,287 42 JUNI 2013 51 30 22 103 223,806 43 JULI 2013 56 37 20 113 238,435 44 AGUSTUS 2013 52 22 22 96 140,412 45 SEPTEMBER 2013 59 16 32 107 210,198 46 OKTOBER 2013 81 22 22 125 219,037 47 NOVENBER 2013 48 30 13 91 205,868 48 DESEMBER 2013 48 18 17 83 179,517 49 JANUARI 2014 29 24 13 66 165,253 50 FEBRUARI 2014 41 16 12 69 171,463 51 MARET 2014 82 29 8 119 214,587 52 APRIL 2014 38 18 45 101 208,842 53 MEI 2014 76 36 31 143 179,881 54 JUNI 2014 99 29 19 147 155,282 55 JULI 2014 29 32 25 86 132,986 56 AGUSTUS 2014 65 36 23 124 152,568 57 SEPTEMBER 2014 53 37 25 115 201,212 58 OKTOBER 2014 50 18 24 92 203,423 59 NOVENBER 2014 24 16 14 54 183,351 60 DESEMBER 2014 59 21 18 98 166,048 61 JANUARI 2015 38 17 12 67 174,834 62 FEBRUARI 2015 26 20 15 61 154,563 63 MARET 2015 53 6 27 86 140,224 64 APRIL 2015 86 7 11 104 133,466 65 MEI 2015 18 8 28 54 144,960 66 JUNI 2015 58 13 16 87 202,993 67 JULI 2015 45 11 48 104 142,439 68 AGUSTUS 2015 39 20 36 95 198,159 69 SEPTEMBER 2015 102 13 14 129 171,513 70 OKTOBER 2015 47 12 8 67 186,079 71 NOVENBER 2015 54 4 18 76 186,653 72 DESEMBER 2015 31 9 12 52 137,270

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Lampiran 10. P-Chart Total 3 Defect Ban LT Tahun 2010-2015 1. P-Chart sebelum revisi

2. P-Chart revisi 1

5. P-Chart revisi 4 (Proses Stabil)

Sample Prop ortio n 71 64 57 50 43 36 29 22 15 8 1 0.0010 0.0009 0.0008 0.0007 0.0006 0.0005 0.0004 0.0003 _ P=0.0005602 UCL=0.0007518 LCL=0.0003686 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Tests performed with unequal sample sizes

Sample Prop ortio n 46 41 36 31 26 21 16 11 6 1 0.0007 0.0006 0.0005 0.0004 0.0003 _ P=0.0005247 UCL=0.0007101 LCL=0.0003393 1 1 1 1 1

Sample Propo rtion 45 41 37 33 29 25 21 17 13 9 5 1 0.0007 0.0006 0.0005 0.0004 0.0003 _ P=0.0005138 UCL=0.0006972 LCL=0.0003303 1

Sample Prop ortio n 41 37 33 29 25 21 17 13 9 5 1 0.0007 0.0006 0.0005 0.0004 0.0003 _ P=0.0005096 UCL=0.0006924 LCL=0.0003269 1

Sample Pro por tion 41 37 33 29 25 21 17 13 9 5 1 0.0007 0.0006 0.0005 0.0004 0.0003 _ P=0.0005065 UCL=0.0006886 LCL=0.0003243

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Lampiran 11. P-Chart Defect UC Ban LT Tahun 2010-2015 1. P-Chart sebelum revis

i

Sample Pro por tion 71 64 57 50 43 36 29 22 15 8 1 0.0007 0.0006 0.0005 0.0004 0.0003 0.0002 0.0001 _ P=0.0002806 UCL=0.0004162 LCL=0.0001450 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Sample Pro por tion 55 49 43 37 31 25 19 13 7 1 0.00045 0.00040 0.00035 0.00030 0.00025 0.00020 0.00015 0.00010 _ P=0.0002692 UCL=0.0004021 LCL=0.0001364 1 1

por tion 0.00040 0.00035 0.00030 0.00025 _ P=0.0002577 UCL=0.0003876

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Lampiran 12. P-Chart Defect LB Ban LT Tahun 2010-2015 1. P-Chart sebelum revisi

Sample Pro por tion 71 64 57 50 43 36 29 22 15 8 1 0.00035 0.00030 0.00025 0.00020 0.00015 0.00010 0.00005 0.00000 _ P=0.0001449 UCL=0.0002423 LCL=0.0000474 1 1 1 1 1 1 1 1 1 1

Sample Pro por tion 61 55 49 43 37 31 25 19 13 7 1 0.00025 0.00020 0.00015 0.00010 0.00005 _ P=0.0001376 UCL=0.0002325 LCL=0.0000426 1 1 1 1 1

Sample Pro por tion 55 49 43 37 31 25 19 13 7 1 0.00025 0.00020 0.00015 0.00010 0.00005 _ P=0.0001305 UCL=0.0002229 LCL=0.0000380

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Lampiran 13. P-Chart Defect UCB Ban LT Tahun 2010-2015 1. P-Chart sebelum revisi

Sample Pro por tion 71 64 57 50 43 36 29 22 15 8 1 0.00035 0.00030 0.00025 0.00020 0.00015 0.00010 0.00005 0.00000 _ P=0.0001347 UCL=0.0002287 LCL=0.0000407 1 1 1 1 1 1 1 1 1 1 1 1 1

Sample Pro por tion 55 49 43 37 31 25 19 13 7 1 0.00025 0.00020 0.00015 0.00010 0.00005 0.00000 _ P=0.0001242 UCL=0.0002145 LCL=0.0000340 1 1 1 1

Sample Pro por tion 55 49 43 37 31 25 19 13 7 1 0.00020 0.00015 0.00010 0.00005 0.00000 _ P=0.0001213 UCL=0.0002105 LCL=0.0000321

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Lampiran 14. Tabel Konversi DPMO-SIGMA

DPMO NILAI SIGMA DPMO NILAI SIGMA

158.633 2,50 2.555 4,30 146.859 2,55 2.186 4,35 135.666 2,60 1.866 4,40 125.072 2,65 1.589 4,45 115.070 2,70 1.350 4,50 105.650 2,75 1.144 4,55 96.800 2,80 968 4,60 88.508 2,85 816 4,65 80.757 2,90 687 4,70 73.529 2,95 577 4,75 66.807 3,00 483 4,80 54.799 3,10 404 4,85 49.471 3,15 337 4,90 44.565 3,20 280 4,95 40.059 3,25 233 5,00 35.930 3,30 193 5,05 32.257 3,35 159 5,10 28.717 3,40 131 5,15 25.588 3,45 108 5,20 22.750 3,50 89 5,25 20.182 3,55 72 5,30 17.865 3,60 59 5,35 15.778 3,65 48 5,40 13.904 3,70 39 5,45 12.225 3,75 32 5,50 10.724 3,80 26 5,55 9.387 3,85 21 5,60 8.198 3,90 17 5,65 7.143 3,95 13 5,70 6.210 4,00 11 5,75 5.386 4,05 9 5,80 4.661 4,10 7 5,85 4.024 4,15 5 5,90 3.467 4,20 4 5,95 2.980 4,25 3 6,00

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Lampiran 15. Base Line Kinerja Defect Dari Semua Proses Produksi LT 2010-2015

NO. BULAN 2010 2011 2012 2013 2014 2015 TOTAL 1 JANUARI 225,572 195,890 165,322 191,430 165,253 174,834 1,118,301 2 FEBRUARI 207,158 185,883 163,682 182,956 171,463 154,563 1,065,705 3 MARET 225,572 195,080 186,955 205,866 214,587 140,224 1,168,284 4 APRIL 223,620 172,764 174,660 211,631 208,842 133,466 1,124,983 5 MEI 231,782 169,702 171,322 225,287 179,881 144,960 1,122,934 6 JUNI 200,690 190,416 169,410 223,806 155,282 202,993 1,142,597 7 JULI 226,572 199,400 174,192 238,435 132,986 142,439 1,114,024 8 AGUSTUS 212,305 151,361 119,577 140,412 152,568 198,159 974,382 9 SEPTEMBER 130,957 135,362 176,000 210,198 201,212 171,513 1,025,242 10 OKTOBER 217,311 173,963 179,172 219,037 203,423 186,079 1,178,985 11 NOVENBER 198,729 148,719 184,832 205,868 183,351 186,653 1,108,152 12 DESEMBER 200,993 153,477 188,498 179,517 166,048 137,270 1,025,803 TOTAL 2,501,261 2,072,017 2,053,622 2,434,443 2,134,896 1,973,153 13,169,392 NO. BULAN 2010 2011 2012 2013 2014 2015 TOTAL

1 JANUARI 326 234 170 214 157 167 1,268 2 FEBRUARI 336 176 214 202 184 172 1,284 3 MARET 256 328 180 316 253 166 1,499 4 APRIL 279 208 161 237 298 181 1,364 5 MEI 283 319 159 342 279 130 1,512 6 JUNI 462 377 129 279 280 183 1,710 7 JULI 282 359 149 258 204 161 1,413 8 AGUSTUS 298 267 151 220 265 179 1,380 9 SEPTEMBER 182 229 177 323 225 205 1,341 10 OKTOBER 310 300 157 260 203 200 1,430 11 NOVENBER 341 161 189 205 169 192 1,257 12 DESEMBER 280 151 166 182 206 165 1,150 TOTAL 3,635 3,109 2,002 3,038 2,723 2,101 16,608

NO. ITEM TAHUN AVERAGE

2010 2011 2012 2013 2014 2015 1 _PRODUKSIJUMLAH 2,501,261 2,072,017 2,053,622 2,434,443 2,134,896 1,973,153 2,194,899 2 JUMLAH _DEFECT 3,635 3,109 2,002 3,038 2,723 2,101 2,768 3 DPMO 32.29 33.34 21.66 27.73 28.34 23.66 27.84 Jumlah defect: Jumlah Produksi:

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NO. BULAN 2010 2011 2012 2013 2014 2015 TOTAL 1 JANUARI 183 212 151 192 133 146 1,017 2 FEBRUARI 293 155 188 169 143 142 1,090 3 MARET 223 298 152 277 225 143 1,318 4 APRIL 239 185 133 216 267 168 1,208 5 MEI 211 273 129 306 248 117 1,284 6 JUNI 312 338 107 251 258 161 1,427 7 JULI 237 255 124 231 184 146 1,177 8 AGUSTUS 269 228 89 201 239 157 1,183 9 SEPTEMBER 165 164 132 276 210 183 1,130 10 OKTOBER 276 170 139 243 190 138 1,156 11 NOVENBER 291 122 174 191 148 170 1,096 12 DESEMBER 219 120 148 159 183 143 972 TOTAL 2,918 2,520 1,666 2,712 2,428 1,814 14,058

NO. BULAN 2010 2011 2012 2013 2014 2015 TOTAL 1 JANUARI 225,572 195,890 165,322 191,430 165,253 174,834 1,118,301 2 FEBRUARI 207,158 185,883 163,682 182,956 171,463 154,563 1,065,705 3 MARET 225,572 195,080 186,955 205,866 214,587 140,224 1,168,284 4 APRIL 223,620 172,764 174,660 211,631 208,842 133,466 1,124,983 5 MEI 231,782 169,702 171,322 225,287 179,881 144,960 1,122,934 6 JUNI 200,690 190,416 169,410 223,806 155,282 202,993 1,142,597 7 JULI 226,572 199,400 174,192 238,435 132,986 142,439 1,114,024 8 AGUSTUS 212,305 151,361 119,577 140,412 152,568 198,159 974,382 9 SEPTEMBER 130,957 135,362 176,000 210,198 201,212 171,513 1,025,242 10 OKTOBER 217,311 173,963 179,172 219,037 203,423 186,079 1,178,985 11 NOVENBER 198,729 148,719 184,832 205,868 183,351 186,653 1,108,152 12 DESEMBER 200,993 153,477 188,498 179,517 166,048 137,270 1,025,803 TOTAL 2,501,261 2,072,017 2,053,622 2,434,443 2,134,896 1,973,153 13,169,392

NO. ITEM ₂₀₁₀ ₂₀₁₁ ₂₀₁₂TAHUN ₂₀₁₃ ₂₀₁₄ ₂₀₁₅ AVERAGE 1 JUMLAH _{PRODUKSI 2,501,261 2,072,017 2,053,622 2,434,443 2,134,896 1,973,153} 2,194,899 2 JUMLAH _DEFECT 2,918 2,520 1,666 2,712 2,428 1,814 2,343 3 DPMO 41.66 43.44 28.97 39.79 40.62 32.83 37.89 4 LEVEL _SIGMA 5.43 5.42 5.52 5.45 5.44 5.49 5.46 Jumlah defect: Jumlah Produksi:

Lampiran 16. BaseLine Kinerja Defect Proses Curing Tahun 2010-2015

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Lampiran 17. Tabel Base Line Kinerja 3 Defect CTQ

NO. ITEM DEFECT AVERAGE

3 CTQ UC LB UCB

1 Opportunity _{( OP )} 3 1 1 1 1

2 _{Produksi ( U ) 13,169,392 13,169,392 13,169,392 13,169,392 13,169,392}Jumlah 3 Defect ( D ) 7,377 3,695 1,908 1,774 2,459 4 DPU ( Defect _{per Unit )} 0.00056 0.00028 0.00014 0.00013 0.00019 5 Opportunity Total per

( TOP ) 39,508,176 13,169,392 13,169,392 13,169,392 13,169,392 6 Opportunity Defect per

( DPO ) 0.000187 0.000281 0.000145 0.000135 0.000187

7 DPMO 186.72 280.57 144.88 134.71 186.72

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Lampiran 18. Penentuan Target Kinerja

Based On Jumlah Produksi : 13,169,392 TARGET

PCS TARGET PPM TARGET L. SIGMA

3,437 261 4.97

1,528 116 5.18

1,356 103 5.21

NO. ITEM DEFECT

3 CTQ UC LB UCB

1 Opportunity ( OP ) 3 1 1 1

2 Jumlah Produksi _(U) 13,169,392 13,169,392 13,169,392 13,169,392

3 Defect (D) 7,377 3,437 1,528 1,356

4 DPU (Defect /Unit ) 0.00056 0.00026 0.00012 0.00010 5 Total per Opportunity _(TOP) 39,508,176 13,169,392 13,169,392 13,169,392 6 _{Opportunity ( DPO )}Defect per 0.000187 0.000261 0.000116 0.000103

7 DPMO 186.72 261.00 116.00 103.00

(20)

Lampiran 19. Data Level Sigma Industri

Sumber: Vincent Gaspers(2011)

(21)

Lampiran 20. Data Bench Marking Industri Tire

Rara-rata data tahun 2015

NO. ITEM AutoMobilel _Tire Tube Tire _{Cycle Tire}Motor

1 Opportunity ( OP ) 1 1 1

2 Jumlah Produksi ( U ) 45,000 15,000 90,000

3 Defect ( D ) 59 24 180

4 DPU ( Defect per Unit ) 0.00130 0.00160 0.00200 5 Total per Opportunity ( TOP ) 45,000 15,000 90,000 6 Defect per Opportunity ( DPO 0.001300 0.001600 0.002000

7 DPMO 1300 1600 2000

8 Level Sigma 4.51 4.45 4.38

(22)

Lampiran 21. Data Defect Under Cure Januari-Maret 2016

UNDER CURE JANUARI 2016

NO. PENYEBAB JUMLAH

1 Over load 21

2 Internal pressure drop 8

3 Platen temperature drop 4

4 Internal pressure no up 4

5 Timer tidak kerja 4

6 Second Shapping tidak kerja 3 7 HW uncirkulasi tidak kerja 2 9 Internal pressure lambat up 2 10 Internal temperature no up 2

TOTAL 50

UNDER CURE FEBRUARI 2016

NO. PENYEBAB JUMLAH

1 Temperature platen drop 10

2 Overload 10

3 Internal pressure tidak masuk 10

TOTAL 42

UNDER CURE MARET 2016

NO. PENYEBAB JUMLAH

1 Over load 10

2 Temperature platen under 9

4 Internal platen drop 5

5 Internal pressure tidak masuk 5

7 Second Shapping tidak kerja 2

(23)

Lampiran 22. Defect LB dan UCB Januari-Maret 2016

LEAKY BLADDER JANUARI 2016

NO. PENYEBAB JUMLAH

1 Bladder bocor reversion 9 2 Bladder bocor cacat 2

3 Bladder bocor tua 1

TOTAL 12

LEAKY BLADDER FEBRUARI 2016

NO. PENYEBAB JUMLAH

1 Bladder bocor reversion 11 2 bladder bocor cacat 1

TOTAL 12

LEAKY BLADDER MARET 2016

NO. PENYEBAB JUMLAH

1 Bladder bocor reversion 10 2 bladder bocor cacat 2

3 Bladder bocor tua 1

TOTAL 13

UNDER CURE BEAD JANUARI 2016

NO PENEBAB JIMLAH

1 Head Cylinder Bocor 10

2 Seal Bladder bawah Putus 6 3 Seal Bladder atas gompal 2

TOTAL 18

UNDER CURE BEAD FEBRUARI 2016

NO PENEBAB JIMLAH

2 Seal Bladder atas gompal 3 3 Seal Bladder Bawah putus 2

TOTAL 15

UNDER CURE BEAD MARET 2016

NO PENEBAB JIMLAH

2 Seal Bladder atas gompal 7 3 Seal Bladder Bawah putus 5

(24)

Lampiran 23. Perhitungan Level Sigma Januari –Maret 2016

DATA JANUARI 2016

NO. ITEM UC LB UCB

3 Defect ( D ) 50 12 16

4 DPU ( Defect per Unit ) 0.00027 0.00007 0.00009 5 Total per Opportunity ( TOP ) 182,526 182,526 182,526 6 Defect per Opportunity ( DPO ) 0.000274 0.000066 0.000088

7 DPMO 274 66 88

8 Level Sigma 4.96 5.32 5.25

DATA FEBRUARI 2016

NO. ITEM UC LB UCB

3 Defect ( D ) 42 12 15

7 DPMO 234 67 83

8 Level Sigma 5.00 5.32 5.26

DATA MARET 2016

NO. ITEM UC LB UCB

3 Defect ( D ) 41 13 19

7 DPMO 215 79 100

(25)

Lampiran 24. Usulan Penanganan Defect Tyre

Diketahui ada defect tyre

Stop Mesin

Sisa tyre di MC dikirim ke FI untuk dicheck Team Leader ATC ATC / AFI Operator ATC Analisa Tyre ( cut sample ) Analisa Mesin ( problem mesin ) ATC / AQC / PE Materia l Ganti Lot NG OK Mesin Perbaikan OK Test Cure ATC / PE NG Check Tyre NG NG ATC

AQC / AFI / ATC / PE

OK OK

Mass Pro ATC

OK

PICI FLOW PROCCES