By Theodora Savitri
11507001
BACHELOR’S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
Revision after Thesis Defense on 9th July 2019
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Theodora Savitri
_____________________________________________
Student Date
Approved by:
Dr. Eng. Aditya T. Pratama, S.Si, M.T.
_____________________________________________
Thesis Advisor Date
Ir. Triarti Saraswati, M.Eng.
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc.
_____________________________________________
IMPROVING QUALITY OF MEDIUM VOLTAGE PRODUCTION IN CABLE COMPANY
By Theodora Savitri
Dr. Eng. Aditya T. Pratama, S.Si, M.T., Advisor Ir. Triarti Saraswati, M.Eng., Co-Advisor
SWISS GERMAN UNIVERSITY
Medium Voltage cable is a power distribution cable with a range from 2000 to 35,000 volts. Medium Voltage cable is the primary production due to the high level of demand in the company. Quality is the main focus to create smooth production and high-grade quality cable with the aim of minimizing defects and time-consuming reworking processes. Good quality is not solely machine and material; it can be influenced by other aspects (such as organization, environment, and management). The production in current condition has a defect that is only found in certain processes. To increase quality production in a cable manufacturing company, the potential error from several aspects need to reduce. Pareto chart and Fishbone diagram will be used to analyse the defect root-cause using recorded data. This research uses Human Factor Analysis and Classification Systems (HFACS) methodology to analyse potential human errors in this company. HFACS outlined the possibility of error is due to wrong material handling or error in data transfer. A new moving system tool was decided to be an effective solution to solve material handling problems and business process improvement is made as a new standard procedure to eliminate a potential error in data transferring.
Keywords: Quality, Human Error, Human Factor Analysis and Classification System, Business Process Improvement.
© Copyright 2019 by Theodora Savitri
All rights reserved
DEDICATION
I dedicate this works for my family, friends and the future me.
ACKNOWLEDGEMENTS
First of all, the author would like to express her deepest gratitude to Dr. Eng. Aditya T.
Pratama, S.Si, M.T. and Ir. Triarti Saraswati, M.Eng. for all valuable guidance and advice through the creation of this thesis. Thanks to all the lecturers that already share their knowledge in the past four years.
The author would like to thank Mr. Djohanes, who helped the author to get permission doing this research in his company. Thanks to the company for their willingness and readiness to provide an opportunity to use their company for thesis research purposes.
Mr. Bambang and Mr. Hermawan were always ready to answer all the questions and info needed.
Time spent in Swiss German University from semester one until semester eight would not be fun and colourful without the presence of my fellow friends in Industrial Engineering 2015. Their presence and support were greatly appreciated.
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
Table of Contents ... 7
List of Figures ... 10
List of Tables ... 12
CHAPTER 1 – INTRODUCTION ... 13
1.1 Background ... 13
1.2 Research Problems ... 14
1.3 Research Objectives ... 14
1.4 Significance of Study ... 15
1.5 Research Questions ... 15
1.6 Research Scope and Limitation ... 15
1.7 Thesis Organization... 15
1.8 Thesis Timeline ... 16
CHAPTER 2 – LITERATURE REVIEW ... 17
2.1 Quality ... 18
2.2 Quality Control ... 18
2.3 Lean ... 18
2.3.1 Principles of Lean ... 19
2.3.2 Theory of Waste ... 19
2.4 Define – Measure – Analyse – Improve – Control (DMAIC) ... 21
2.5 Seven Basic Tools of Quality ... 21
2.5.1 Check Sheet ... 21
2.5.2 Control Chart ... 22
2.5.3 Flow Chart ... 23
2.5.4 Pareto Chart ... 23
2.5.5 Histogram ... 24
2.5.6 Fishbone Diagram ... 25
2.5.7 Scatter Diagram ... 26
2.6 Human Failure ... 26
2.7 Human Factor Analysis and Classification System ... 27
2.8 Business Process Improvement ... 30
CHAPTER 3 – RESEARCH METHODS ... 31
3.1 Define ... 32
3.1.1 Problem Identification ... 32
3.1.2 Literature Review... 32
3.1.3 Research Design... 32
3.2 Measure ... 32
3.2.1 Data Acquisition ... 32
3.2.2 Data Processing ... 33
3.3 Analysis ... 33
3.3.1 Data Analysis ... 33
3.4 Improve ... 33
3.4.1 Proposed Improvement ... 33
3.5 Control ... 34
3.5.1 Result and Discussion ... 34
CHAPTER 4 – RESULT AND DISCUSSION ... 35
4.1 Company Overview... 35
4.2 Product Overview ... 37
4.3 Medium Voltage Cable Production Process... 38
4.3.1 Drawing... 39
4.3.2 Stranding ... 39
4.3.3 Insulation... 40
4.3.4 Screening... 41
4.3.5 Cabling ... 42
4.3.6 Inner Sheath ... 43
4.3.7 Armour Sheath ... 43
4.3.8 Outer Sheath and Marking ... 44
4.4 Problem Identification ... 44
4.5 Data Process ... 47
4.6 Root-Cause Analysis ... 49
4.7 Human Factor Analysis and Classification System ... 52
4.8 Proposed Improvement ... 58
4.8.1 Material Handling ... 59
4.10 Result ... 68
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 69
5.1 Conclusions ... 69
5.2 Recommendations ... 70
REFERENCES ... 71
APPENDIX A – Medium Voltage Defect Check Sheet ... 72
APPENDIX B – Human Factor Analysis and Classification System ... 73
CURRICULUM VITAE ... 75
