By
HASANUDDIN 2-1952-043
MASTER’S DEGREE in
MASTER OF MECHANICAL ENGINEERING-ENGINEERING MANAGEMENT FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
June 2021
Revision after thesis defense on July 13th 2021 6 Mei 2019
Hasanuddin ABSTRACT
REDUCING SCRAP OF CEMENT A3CM-05 BY USING PDCA (PLAN DO CHECK ACTION) AND QCC (QUALITY CONTROL CIRCLE) METHOD IN AN
INDONESIA LEADING TIRE
By Hasanuddin
Dr. Ir. Gembong Baskoro, M.Sc., Advisor Dr. Eng. Aditya Tirta Pratama, S.Si, M.T., Co-Advisor
SWISS GERMAN UNIVERSITY
Manufacturing companies that run the business never abandon efforts to make efficiency and increase productivity. Increasing productivity within the company is the primary purpose but producing A3CM-05 cement leaves scrap/waste due to inefficient work methods. This study aims to reduce scrap/waste in the A3CM-05 cement production process by designing a method to increase efficiency, which will be implemented by PDCA (Plan, Do, Check, Action) & QCC (Quality Control Circle) method. The improvement will be focused on problems with serious scrap/waste above the specified target (Key Performance Indicator). For the result, the main factors of non- conformance will be identified, such as methods, materials, and people, and how to maintain the improvements by using work instructions and check sheets. This study provides an improved solution to the result base on root cause analysis of the problem.
These improvements, such as an increase in productivity by 2.1%, and the scrap generated from the remaining cement production decreased by 8.76% from the original 38.87% to 30.11% per month in the cement process of A3CM-05.
Keywords: PDCA, QCC, Scrap, Productivity, A3CM-05
Hasanuddin
© Copyright 2021 by Hasanuddin All rights reserved
Hasanuddin 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 acknowledgment is made in the thesis.
Hasanuddin
____________________________________________
Student Date
Approved by:
Dr. Ir. Gembong Baskoro, M.Sc.
____________________________________________
Thesis Advisor Date
Dr. Eng. Aditya Tirta Pratama, S.Si., M.T.
____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc.
____________________________________________
Dean
Date
Hasanuddin DEDICATION
Glory to Allah SWT (Lord of the worlds)! I dedicate this work to my mother, my beloved family, my friends, the company where I work, and my country.
Hasanuddin ACKNOWLEDGEMENTS
Praise and gratitude I pray to the presence of God Almighty for His mercy and grace. I was able to complete this thesis on time and on time. This thesis can also be completed with the help and support of various parties. Therefore, I would like to thank those who have helped in the writing of this thesis, namely:
1. My family my Parents father, mother, brothers, and sisters who always support and pray for their children, especially my mother (Richania)
2. Management of PT Gajah Tunggal Tbk, which has given me the opportunity to participate in the master program.
3. Dr. Ita Mariza as Director of Politeknik Gajah Tunggal, which has facilitated the implementation of this scholarship program.
4. Srijaya as the head of Bias Tire & Tube Plant, which has given me the opportunity to participate in the master program.
5. Dr. Ir. Gembong Baskoro, M.sc as SGU's SDC Director and as Advisor who always provides motivation and education
6. Dr. Aditya Tirta Pratama, S.Si., M.T., as a co-supervisor who has given time to guide, enlighten, assist, support me during the process of completing this thesis.
7. Ali Mustofa, S.T., M.M., as the head of the Quality Control Department who gave me the opportunity to do this research, which gave me permission to continue my education.
8. Lukas Firmanto, S.T., as Assistant to the head of the Department of Quality Control, Section Cement House and Final inspection who has given permission and opportunity for me to continue my education.
9. Management Bias Tire Cement Plant, including Asst Dept Head, Section Head, and fellow employees of the Cement House section has allowed me and helped me to do this research.
Hasanuddin support during their studies.
The author hopes that God will always bestow His grace and gifts to all those who have helped the author. Hopefully, this thesis can provide benefits for writers, readers, and the development of science.
Hasanuddin TABLE OF CONTENTS
Page
ABSTRACT...2
STATEMENT BY THE AUTHOR ...4
DEDICATION ...5
ACKNOWLEDGEMEN TS ...6
TABLE OF CONTENTS ...8
LIST OF FIGURES ... 11
LIST OF TABLE...13
CHAPTER 1 – IN TRODUCTION ...14
1.1 Background ...14
1.2 Research Problems...17
1.3 Research Objectives...18
1.4 Significance of Study...18
1.5 Research Question ...18
1.6 Research Scope and Limitations...18
1.7 Research Timeline ...18
CHAPTER 2 – LITERATURE REVIEW...20
2.1 Research Mind Map...20
2.2 Tire Manufacturing Process ...20
2.3 Process O f Cement A3CM-05 ...22
2.4 Quality ...25
2.5 PDCA (Plan, Do, Check, Action) ...25
2.5.1 PDCA Cycle ...26
2.5.2 Advantages of PDCA ...27
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2.6 Quality Control Circle (QCC) ...29
2.6.1 Definition Quality Control Circle (QCC) ...29
2.6.2 Basic Organizational Structure of QCC ...29
2.6.3 Eight (8) steps for improvement ...30
2.6.4 Seven (7) tools used in implementing the improvement (QCC) ...31
CHAPTER 3 – RESEARCH METHODOLOGY ...37
3.1 Research Framework ...37
3.1.1 Problem Identification/Theme ...38
3.1.2 Setting targets ...38
3.1.3 Existing condition analysis ...38
3.1.4 Cause and effect analysis...39
3.1.5 Improvement plan...39
3.1.6 Implementation of the improvement plan ...39
3.1.7 Evaluation of improvement results...39
3.1.8 Standardization and Future Plan...40
3.1.9 Conclusion ...40
3.2 Research Instruments ...40
CHAPTER 4 – RESULT AND DISCUSSION...43
4.1 Plan ...43
4.1.1 Determine the Theme ...43
4.1.2 Determine the Target ...44
4.1.3 Conduct and Analysis of Existing Conditions ...45
4.1.4 RCA (Root Cause Analysis) ...46
4.1.5 Planning countermeasures ...47
4.2 DO (Implement corrective and preventive actions)...48
4.2.1 First improvement ...48
4.2.2 Second improvement ...50
4.2.3 Third improvement ...50
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4.2.4 Fourth improvement ...52
4.2.5 Fifth improvement ...53
4.3 Check (Evaluation and Result) ...54
4.3.1 Straps found on production after analysis: ...54
4.3.2 Evaluation of the A3CM-05 scrap cement ...55
4.3.3 Evaluation of results using QCDSMPE ...56
4.3.4 Evaluation production time of cement A3CM-05 ...57
4.4 Action ...59
4.4.1 Monitoring of Improvement ...59
4.4.2 Planning to Another Improvement ...60
CHAPTER 5 – CONCLUSION AND RECOMMENDATION ...61
5.1 Conclusion ...61
5.2 Recommendation ...61
REFERENCES ...62
APPENDIX 1 - Analyze using 5W + 2H (What, Why, How, Who, Where, When, and How Much) ...64
APPENDIX 2 – Cement production data A3CM-05 (March & April) ...66
APPENDIX 3 – Cement production data A3CM-05 (April- May) ...67
APPENDIX 4 – Cement production data A3CM-05 (May-Jun) ...68
APPENDIX 5 – Attendance list + photo Interview and Meeting together ...69
CURRICULUM VITAE ...70
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Figure 1. 1 Scrap per cement product ... 15
Figure 1. 2 Cement A3CM-05 vs Scrap ... 16
Figure 1. 3 Cement A3CM-05 scrap vs scrap target KPI... 16
Figure 1. 4 Cement A3CM-05 VS Scrap cement A3CM-05... 17
Figure 2. 1 Research Mind Map ... 20
Figure 2. 2 Manufacturing Flow Process Bias tires ... 21
Figure 2. 3 Bias Tire... 22
Figure 2. 4 Types of defects/scrap Bias tires... 22
Figure 2. 5 Manufacturing Process Cement A3CM-05 ... 23
Figure 2. 6 Not Good Appearance cement A3CM-05... 25
Figure 2. 7 PDCA Cycle ... 26
Figure 2. 8 Figure 2. 5 Pyramid QCC ... 29
Figure 2. 9 Fishbone Diagram Example ... 32
Figure 2. 10 Pareto Chart Example ... 33
Figure 2. 11 Scatter Diagram ... 34
Figure 2. 12 Histogram Example ... 35
Figure 2. 13 Control Chart ... 36
Figure 2. 14 Stratification Example ... 36
Figure 3. 1 Research Methodology Flow Process ... 37
Figure 3. 2 Weighing Scale ... 41
Figure 3. 3 Visco cup ... 41
Figure 3. 4 Stop Watch ... 42
Figure 3. 5 HVS Paper ... 42
Figure 4. 1 Percentage of scrap from the production process ... 43
Figure 4. 2 Total production vs scrap ... 44
Figure 4. 3 Fishbone diagram high scrap ... 46
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Figure 4. 4 Components of the cement production process A3CM-05... 47
Figure 4. 5 Visual Work Instruction for Mixer Machine Cleaning ... 49
Figure 4. 6 Cement Filter ... 50
Figure 4. 7 Cement Stirrer... 50
Figure 4. 8 Visual Work Instruction for Cement A3CM-05 Screening Process ... 51
Figure 4. 9 Warning Cement Screening Process ... 54
Figure 4. 10 Percentage of achievement of scrap target ... 55
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Table 1.1 Time Frame of Study... 19
Table 2. 1 Comparison between PDCA and DMAIC ... 28
Table 2. 2 Check Sheet Example ... 31
Table 2. 3 The N umber of Incidents for Each Cause Tabulated ... 33
Table 4. 1 Finding problems and effects ...45
Table 4. 2 Improvement Plan ... 48
Table 4. 3 Specification of A3CM-05 Cement Material ... 52
Table 4. 4 Material cost before and after Improvement ... 53
Table 4. 5 Average cement production of A3CM-05 after repair... 54
Table 4. 6 Analysis results QCDSMPE... 56
Table 4. 7 Environmental odor measurement ... 57
Table 4. 8 Cement A3CM-05 processing time ... 58
Table 4. 9 Standardization of Improvement ... 59
Table 4. 10 Monitoring of Improvement... 60
