By Ronaldi 11407004
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
August 2018
Revision After Thesis Defense on 20nd July 2018
Ronaldi 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.
Ronaldi
_____________________________________________
Student
Date
Approved by:
Ir. Setijo Awibowo, M.M.
_____________________________________________
Thesis Advisor Date
Edo Suryo Pratomo, S.T., M.Sc.
_____________________________________________
Thesis Co-Advisor Date
Dr. Irvan Setiadi Kartawiria, S.T., M.Sc.
_____________________________________________
Dean Date
Ronaldi ABSTRACT
DEVELOPING A NEW STANDARD OPERATION PROCEDURE (SOP) FOR REWORK IN QUALITY PART CHECKING
By Ronaldi
Ir. Setijo Awibowo M.M., Advisor , Co-Advisor
SWISS GERMAN UNIVERSITY
In the automotive industry, surely company need to produce the car with the good quality and every year the company have to developing and improving the product in order serve the customer and get the highest demand. The most important thing and also the basic for the company to get the good product is from the quality control.
Mostly the resources, materials and tools are controlled by the Quality Control for analyse and prevent from defect in production line, it seems like QC is similar with QA ( Quality Assurance) but actually QC is being backed up by QA because it implement Quality Control as the Standard Operating Procedure (SOP). The standardization must be set in production line in order to prevent the material part are defect and then assembled to the body car, it will make the product become NG (not good) and there will be some recall statement to take over all the product that has been produced. As Quality Control set the standard for the part to be input into the assembly line, if there are some problem about the quality part the QC must analyze and plan to improving in order to keep up standard of the quality based on ISO 9001:2015 (the standardization for the quality management).
Keywords: Root cause analysis, SOP, Digitalization Support, PDCA.
Ronaldi
© Copyright 2018 by Ronaldi All rights reserved
Ronaldi DEDICATION
I dedicate this thesis to God for let me done this thesis. My family who always support me, motivate me until this thesis is finish, then also I give many thanks for all of my lecturers who always guide me from the beginning until last of this thesis done.
Ronaldi ACKNOWLEDGEMENTS
I am here to give thanks and praise to the Lord, because I got the chance to do this thesis research in time. I am really thankful to all of my family because without their support, I cannot complete this report. Also I really appreciate to PT. XYZ who give me a chance to do my thesis research in their company, thank you for the supervisor and the worker who always guide me to do the research, I got a lot of experience and lessons during this Semester. The last I would like to thank you for SGU and the lecturers who gave me the opportunity to do make this thesis report.
Ronaldi TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 9
LIST OF TABLES ... 11
CHAPTER 1 - INTRODUCTION ... 12
1.1. Background ... 12
1.2. Research Problem ... 13
1.3. Research Objectives ... 13
1.4. Significance of Study ... 14
1.5. Thesis Structure ... 14
CHAPTER 2 - LITERATURE REVIEW ... 15
2.1 Quality Management ... 15
2.1.1. Quality Control ... 16
2.1.2. Quality Assurance ... 17
2.2 Rework Process ... 17
2.3 NCP ... 18
2.4 PA/PI ... 18
2.5 Root Caused Analysis ... 19
2.6 Digitalization Support ... 20
2.7 Standard Operating Procedure (SOP) ... 20
2.8 Analytical Hierarchy Process (AHP) ... 21
2.9 PDCA ... 21
2.9.1 Plan ... 22
2.9.2 Do ... 22
2.9.3 Check ... 22
2.9.4 Act ... 22
2.10 Waterfall Methodology ... 23
CHAPTER 3 – RESEARCH METHODOLOGY ... 24
3.1 Research Problem ... 26
Ronaldi
3.1.1 Breakdown The Problem ... 26
3.2 Literature Review ... 26
3.3 Data Acquisition ... 26
3.4 Data Analysis ... 27
3.5 Solve and Implement Solution ... 27
3.5.1 Priority System ... 27
3.5.2 Program Database System ... 28
3.6 Analysis Solution ... 29
3.7 Conclusion and Recommendation ... 29
CHAPTER 4 – RESULT AND DISCUSSION ... 30
4.1 Company Profile ... 30
4.2 Root Cause Analysis ... 30
4.2.1 Current Condition ... 32
4.2.1 General Flow Process of Part ... 35
4.2.2 Considerable Number of Rework Parts ... 44
4.2.3 Supporting Tools for Rework Process ... 46
4.3 Developed Solution ... 47
4.3.1 Developed Priority System ... 47
4.3.2 Develop Work In Progress Board ... 52
4.3.3 Develop Database program ... 53
4.4 Analysis the Solution ... 61
4.4.1 Form Priority System ... 61
4.4.2 Alpha Testing and Create Standard Procedure ... 72
4.4.3 Comparison Supporting Tools ... 73
CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 79
5.1. Conclusion ... 79
5.2. Recommendation ... 80
5.3. Further Improvement ... 80
Appendices ... 81
References ... 103
