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"Penelitian ini bertujuan untuk memberikan perencanaan peningkatan fleksibilitas produksi pada produk dengan unmatching ratio tertinggi pada sebuah perusahaan di Indonesia. Penelitian ini berfokus pada permasalahan ketidakmampuan menyerap fluktuasi order yang dilakukan oleh dealer atau end customer di salah satu perusahaan otomotif ternama di Indonesia. Jika hal itu tidak dapat diatasi, maka akan berpotensi terjadinya cancelation order. Untuk itu, diperlukan perbaikan untuk dapat meningkatkan fleksibilitas produksi perusahaan. Metode yang digunakan dalam penelitian ini adalah DMAIC (Define, Measure, Analyze, Improve & Control) untuk mendapatkan solusi yang tepat. Perbaikan yang dilakukan akan memberikan dampak terhadap opportunity cost dan unmatching ratio. Pada penelitian ini, dibuat skema penyerapan fluktuasi order secara mingguan berupa WOC (Weekly Order Change) dengan melakukan pengadaan safety stock terhadap unique part dengan melakukan perhitungan menggunakan Q-model. Hasil yang didapatkan dari penelitian ini adalah profit sebagai opportunity cost Rp431.635.851 serta penurunan unmatching ratio dari 4,9% pada keadaan sebelum menjadi 1,2% pada keadaan setelah perbaikan

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This study aims to increasing production flexibility on highest unmatching ratio products in a Indonesia company. This study focuses on the problem of an inability to absorb orders fluctuations by dealer or end customer at one of Indonesia's leading automotive companies. If it is not solved, it will potentially causes cancelation order. Therefore, the necessary improvements in order to increase the production flexibility of the company. Method used in this research is DMAIC (Define, Measure, Analyze, Improve & Control) in way to get the right solution. Improvements will have an impact on opportunity cost and unmatching ratio. In this study, absorption scheme fluctuations order on a weekly basis in the form of WOC (Weekly Change Order) with adding a safety stock of unique part by using Q-model calculations. The results obtained from this study is the profit as the opportunity cost IDR431,635,851 and unmatching ratio decrease from 4.9% in before condition become 1.2% in after condition.

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"Produk defektif adalah produk dari hasil produksi yang tidak sesuai standar, tidak dapat dijual, dan tidak dapat digunakan kembali. Risiko terjadinya produk defektif merupakan hal yang tidak dapat dihindari pada proses manufaktur. Dengan adanya risiko tersebut, pemanufaktur perlu menetapkan sasaran mutu produksi yang menjadi parameter kualitas dan performa produksi. Selain kerugian terhadap pemanufaktur, produk defektif juga bertentangan dengan tujuan Sustainable Development Goals (SDGs) yang menyatakan bahwa suatu kegiatan ekonomi harus mencermati isu-isu krusial, seperti dampak terhadap lingkungan akibat limbah produksi. Penelitian ini akan mengidentifikasi dan menilai faktor-faktor penyebab produk defektif dan menawarkan rencana tindakan menggunakan metode Define, Measure, Analyze, Improve, dan Control (DMAIC). Data pada penelitian ini divalidasi menggunakan matriks Failure Mode and Effect Analysis (FMEA) yang disajikan menggunakan Problem Identification and Corrective Action (PICA). Hasil penelitian ini menunjukkan bahwa produk defektif pada proses produksi oleh perusahaan pengemas disebabkan oleh kegagalan fungsi peralatan yang dipengaruhi oleh kurangnya pemeliharaan peralatan dan proses kontrol kualitas. Hasil dari penelitian ini berupa solusi untuk penambahan fungsi alat; memastikan doctor blade dalam kondisi optimal dan sesuai dengan standar acuan proses; meningkatkan konsistensi pemeliharaan; inspeksi dan penggatian rutin alat pneumatic; dan meningkatkan ketelitian kontrol kualitas pada tiap-tiap proses produksi.

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Defective products are products that are not up to standard, cannot be sold, and cannot be reused. The risk of defective products occurring is unavoidable in the manufacturing process. Given these risks, manufacturers need to set production quality targets which are parameters of production quality and performance. In addition to losses to manufacturers, defective products also conflict with the objectives of the Sustainable Development Goals (SDGs) which state that an economic activity must pay close attention to crucial issues, such as the impact on the environment due to production waste. This research will identify and assess the factors that cause defective products and offer an action plan using the Define, Measure, Analyze, Improve, and Control (DMAIC) method. The data in this study were validated using the Failure Mode and Effect Analysis (FMEA) matrix presented using Problem Identification and Corrective Action (PICA). The results of this study indicate that defective products in the production process by packaging companies are caused by equipment malfunctions which are affected by a lack of equipment maintenance and quality control processes. The results of this study are solutions for adding tool functions; ensuring that the doctor blade is in optimal condition and in accordance with process reference standards; improve maintenance consistency; inspection and periodic replacement of pneumatic tools; and improve quality control accuracy in each production process."

"Penelitian ini berfokus pada metode peningkatan kualitas produk dari proses mesin Injection Moulding dengan pendekatan DMAIC Six Sigma. Tujuan dari penelitian ini adalah menganalisa penyebab defect pada proses mesin injection moulding dan mengetahui tindakan perbaikan yang harus dilakukan, untuk meminimalisasi defect yang terjadi agar mendapatkan kualitas terbaik dari produk sehingga perusahaan dapat bersaing dalam pasar dewasa ini, yang dinamis dan kompetitif dan juga dapat memenuhi persyaratan pelanggan. Metode DMAIC Six Sigma terdiri lima tahap utama yaitu fase pendefinisian, fase pengukuran, fase analisa, fase perbaikan dan fase kendali. Analisis dilakukan pada proses mesin Injection Moulding 160 Ton yang menghasilkan produk cacat. Pada akhir penelitian ini, dengan menggunakan analisa Diagram Fishbone yang meliputi: Man, Machine, Material, Methode dan Enviroment diperoleh empat tahapan improvement yaitu pembersihan terhadap screw dan barrel, penggunaan polypropylene (PP) dan material khusus untuk pembersihan screw dan barrel melalui proses purging, penyetingan atau penetapan parameter optimum mesin dan melakukan training secara periodik pada karyawan.

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This research focuses on methods of improving the quality products of the process Injection Moulding machine with the approach of Six Sigma DMAIC method. The purpose of this study was to analyze the cause of the defect in the process of injection molding machines and determine corrective actions that must be performe, to minimize defects that occur in order to get the best quality of products so that the company can compete in today's market, a dynamic and competitive, and also can meet the requirements customers.

Six Sigma DMAIC method consists of five main phases, namely definition phase, the phase measurement, phase analysis, phase improvement and phase control. Analysis was conducted on the 160 Ton Injection Moulding machines that produce defective products.

At the end of this study, by using the Fishbone Diagram analysis include: Man, Machine, Material, Method and Environment are four stages namely the improvement of the screw and barrel cleaning, use of polypropylene (PP) and special materials for cleaning screw and barrel through the purging process, setup or the determination of the optimum parameters of the machine and perform periodic training to employees."

"Pemborosan yang terdapat pada proses penanganan petikemas ekspor di TPK Koja dapat menyebabkan performa tidak efisien. Pemborosan tersebut dapat dieliminasi dengan perpaduan konsep DMAIC, konsep Lean dan Konsep diagram Fishbone. Konsep DMAIC digunakan sebagai panduan urutan untuk memudahkan pengolahan dan analisis data yang terdiri dari lima tahap yaitu : (1) Define, mendefinisikan masalah menggunakan konsep Lean untuk membuat Current Value Stream Mapping dan mengidentifikasi pemborosan yang ada di dalamnya; (2) Measure, penentuan pemborosan yang dapat dieliminasi yaitu pemborosan tipe excessive transportation yang diterjemahkan sebagai aktivitas pengangsuran petikemas; (3) Analyze, proses penyelesaian masalah dengan konsep diagram Fishbone untuk mengetahui akar permasalahan aktivitas pengangsuran petikemas; (4) Improvement, perbaikan yang dilakukan untuk menyelesaikan akar permasalahan aktivitas pengangsuran petikemas dan (5) Control, hasil akhir setelah dilakukan perbaikan dalam bentuk Future Value Stream Mapping yang menunjukkan adanya peningkatan efisiensi proses penanganan petikemas ekspor dalam bentuk penghematan waktu sebesar 105 detik.

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Waste that founded in export container handling process at TPK Koja can causing an inefficient performance. The waste can be eliminated with a fusion concept of DMAIC concept, Lean concept and Fishbone Diagram concept. The DMAIC concept used as a guide to facilitate the processing and analysis data that composed of five stages which is : (1) Define, defining problems by using the Lean concept to make the Current Value Stream Mapping and identifying waste in it; (2) Measure, the waste determination process to find which waste that can be eliminated and the result of waste type that can be eliminated is excessive transportation that known as container shuffling activity; (3) Analyze, the problem solved process by using the Fishbone diagram concept to know root problem that cause the container shuffling activity; (4) Improvement, ideas that used to solve the root problems that cause the container shuffling activity and (5) Control, the final result after the improvement applied that showed the Future Value Stream Mapping and indicates there is an increasing of efficiency in export containers handling process at TPK Koja by saving 105 seconds."

"[Penelitian ini dilakukan pada perusahaan farmasi di Indonesia. Masalah yang dialami oleh perusahaan tersebut adalah rendahnya yield pada lini produksi effervescent selama tahun 2014. Penyelesaian masalah ini dilakukan dengan menggunakan metode Lean-DMAIC. Berdasarkan analisis yang dilakukan, dihasilkan beberapa perbaikan yang diimplementasikan pada mesin, operator, dan material. Hasil penerapan usulan perbaikan tersebut memberikan dampak yang positif bagi perusahaan, antara lain meningkatnya yield sebesar 3,59%, menurunnya waste cost komponen material sebesar 26,79%, dan menurunnya downtime mesin sebesar 74,30%.

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This study is conducted in one of the most well-known pharmaceutical company in Indonesia. Problem starts when effervescent line production yield was too low throughout 2014 so that the targeted yield could not be reached. This study applies Lean-DMAIC method to solve the problem. Lean-DMAIC analysis results in several improvements on machine, operators, and material. Result shows that the implemented improvements give several benefits for company, such as increasing 3,59% yield, reducing 26,79% material waste cost, and reducing 74,30% machine downtime.

, This study is conducted in one of the most well-known pharmaceutical company in Indonesia. Problem starts when effervescent line production yield was too low throughout 2014 so that the targeted yield could not be reached. This study applies Lean-DMAIC method to solve the problem. Lean-DMAIC analysis results in several improvements on machine, operators, and material. Result shows that the implemented improvements give several benefits for company, such as increasing 3,59% yield, reducing 26,79% material waste cost, and reducing 74,30% machine downtime.

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"Reagen merupakan bahan kimia yang dalam istilah kesehatan digunakan untuk mendiagnosis atau mengetahui kondisi kesehatan seseorang. Bahan kimia ini dapat ditemukan di rumah sakit dan laboratorium yang tersebar di seluruh Indonesia. Saat ini, jumlah permintaan reagen di Indonesia terus meningkat seiring dengan adanya peningkatan jumlah fasilitas pelayanan kesehatan. Permintaan yang meningkat tersebut mendorong produsen reagen untuk memiliki kapasitas produksi yang cukup, sehingga dapat selalu memenuhi permintaan pelanggan. Penelitian ini membahas mengenai pengembangan model perencanaan kapasitas produksi suatu perusahaan reagen dengan menggunakan pendekatan simulasi waktu diskrit. Tujuan dari penelitian ini adalah dibuatnya suatu perencanaan kapasitas produksi reagen ketika terjadi peningkatan permintaan sebesar lima puluh kali lipat. Berdasarkan analisis hasil simulasi, diperoleh suatu usulan perencanaan kapasitas produksi yang dapat membantu perusahaan untuk tetap mencapai target produksi dan memenuhi permintaan pelanggan.

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Reagent is chemicals that in health terms used to diagnose or determine a person's health condition. These chemicals can be found in hospitals and laboratories spread all over Indonesia. Currently, the amount reagent demand in Indonesia continues to increase along with the increasing number of health care facilities. Increased demand has prompted manufacturers of reagents to have sufficient production capacity, so as to always meet customer demand. This study discusses about the development of reagent production capacity planning using discrete-event simulation approach. The purpose of this study is to make a reagent production capacity planning when there is increased demand until fifty times. Based on the analysis of simulation result, recommendations of production capacity planning are made to help the company achieving production targets and meeting customer demand."

"ABSTRAKEnterprise Resources Planning (ERP) merupakan sistem yang secara luas diterapkan sebagai tulang punggung di banyak perusahaan jasa dan manufaktur. Pada tahap setelah menerapkan sistem ERP, seringkali tantangan yang nyata akan muncul dan risiko yang lebih kritis dapat terjadi. Risiko yang tidak dinginkan pada tahap setelah menerapkan sistem dapat mengubah keberhasilan awal ERP menuju kegagalan dan mengakibatkan kebangkrutan bisnis perusahaan. Penelitian ini bertujuan untuk melakukan penilaian terhadap risiko dan membentuk prioritas kontrol risiko setelah menerapkan sistem ERP pada industri di Indonesia. Penelitian ini menggunakan pendekatan Define-Measure-Analyze-Improve-Control (DMAIC), metode Failure Mode and Effect Analysis (FMEA), Performance Evaluation Matrix (PEM), dan Quality Function Deployment (QFD) yang melibatkan dua pendapat ahli, 68 responden,. Hasil dari penelitian ini adalah ditemukannya 20 risiko yang berada di luar zona kinerja. Metode QFD menghasilkan 5 prioritas kontrol risiko setelah menerapkan sistem ERP.

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ABSTRACTEnterprise Resource Planning (ERP) is a system widely implemented as the backbone in many services and manufacturing industries. At the post-implementation stage, real challenges arise and more critical risks can occur. Unwanted risks in ERP post-implementation can change the initial success of ERP to failure and can also lead to bankruptcy of company's business. The purpose of this study is to assess risk and establish a risk control on post-implemention of ERP in Indonesian Industries. This study uses the Define-Measure-Analyze-Improve-Control (DMAIC) approach, Failure Mode and Effect Analysis (FMEA), Performance evaluation matrix (PEM), and Quality Function Deployment (QFD) method, that involves two expert opinions, 68 respondents. The results of study showed 20 risks beyond the performance zone. QFD method resulted 5 risk control priorities on ERP post-implemention"

"This research taken from abnormality problem that happened in Imported Component Distribution of Automotive Industry in Indonesia. Overall, the abnormalities causing in loss of distribution costs from Drop Point to Warehouse by 41 container deliveries or equivalent to Rp 91.000.000,00 per month. With DMAIC Methodology, the solution are new standard minimum stock calculation based on production volume increased and heijunka pattern (load leveling) on the packing of component in accordance with production need. In the case of minivan product that imported from Thailand 1, the abnormalities can be reduced by Rp 30.800.000,00 or equivalent with 14 container deliveries.

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Penelitian ini diangkat dari masalah abnormalitas operasi pada distribusi komponen impor industri otomotif di Indonesia. Secara keseluruhan, abnormalitas operasi tersebut menyebabkan kerugian biaya distribusi dari Drop Point ke Gudang Bahan Baku sebesar 41 delivery kontainer atau setara Rp 91.000.000,00 per bulan. Pendekatan DMAIC digunakan untuk mendapatkan usulan perbaikan berupa perhitungan standar stok minimum baru dengan memerhatikan kenaikan volume produksi dan membuat pola heijunka (perataan beban) pada bagian pengepakan komponen dalam kontainer yang sesuai dengan kebutuhan produksi. Untuk kasus produk minivan pada importir Thailand 1, dapat dilakukan penurunan biaya abnormalits operasi sebesar Rp 30.800.000,00 atau setara dengan 14 delivery kontainer."

"Proses produksi sebuah produk saat ini sudah mulai merambah ke aspek lingkungan. Hal ini disebabkan banyaknya isu lingkungan yang ramai dibicarakan di masyarakat sehingga aspek lingkungan ini akan menjadi parameter yang cukup penting dari sisi perspektif pelanggan. Untuk menjaga nilai aspek lingkungan tersebut dapat digunakan sistem produksi rantai tertutup (closed loop supply chain) yang dapat meminimalisasi penggunaan sumber daya alam. Selain itu, secara teori, penerapan rantai suplai loop tertutup merupakan salah satu cara untuk meningkatkan efisiensi dari penggunaan bahan baku dari sebuah lini produksi yang akan dapat mengurangi jumlah bahan baku yang digunakan untuk keperluan produksi. Akan tetapi dalam penerapannya closed loop supply chain masih memiliki banyak kendala. Salah satunya adalah dalam hal perencanaan inventory.Karena pengembalian produk dari returnable product berfluktuasi, maka kapasitas inventory yang optimal dari returnable product tersebut sulit untuk ditentukan. Untuk memecahkan masalah ini dapat digunakan metode fixed time period model dan discrete event modelling. Dengan menggunakan discrete event modelling pola pergerakan returnable products akan dapat di telusuri dengan melihat faktor-faktor apa saja yang mempengaruhi produksi dan dengan metode fixed time period model akan dapat ditentukan jumlah quantity order yang optimal pada suatu rentang waktu.

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Production process of products today not only focused on quality and quantity, but also start to concern the environmental issues. "Environmental issues" become an important aspect from the costumer?s perspective. In order to perserve this environmental aspects, closed-loop supply chain become a popular concept in this recent decades. Through closed-loop supply chain, the usage of natural resources could be reduced. Further to production line, the implementation of closed-loop supply chain is one way to improve the efficiency level of raw materials usage of a production line. Because, in closed-loop supply chain, the used product that collected from the costumer will be used again for next production process. However, the implementation of closed loop supply chain still has many obstacle, inventory planning is one of considered obstacles. This problem happened due to uncertainity of returning rate of returnable product that resulting inaccuracy of inventory planning. In order to solve this problem, the combination of discrete event modelling and fixed time period model approach can be used. Through discrete event modelling, the movement pattern and factors of retunable product can be traced and through fixed time period model can be determined the optimum order quantity in certain time limit."

"[ABSTRAKPenelitan ini bertujuan untuk memberikan usulan perbaikan terhadappemenuhan permintaan perbaikan karoseri pada sebuah perusahaan transportasi diIndonesia. Penelitian ini berfokus pada permasalahan tidak terpenuhinyapermintaan perbaikan pada pabrik perbaikan karoseri di salah satu perusahaantransportasi di Indonesia. Perusahaan ini mendapatkan permintaan dari sembilanpool yang tersebar di Jakarta dan Jawa Barat. Sehingga membuat permintaanperbaikan karoseri yang semakin bertambah. Oleh karena itu diperlukan sebuahperbaikan pada proses produksi di PT Primajasa Perdanarayautama. Metode yangdigunakan dalam penelitian ini adalah DMAIC (Define, Measure, Analyze,Improve, dan Control) untuk mendapatkan solusi yang terbaik untuk dapatdiimplementasi. Penelitian ini akan berfokus pada proses painting yang terbagimenjadi enam aktifitas besar, yaitu pembersihan pelat, efoxy primer,pendempulan, cat/painting, vernis dan finishing. Perbaikan yang dilakukan akanmemberikan dampak terhadap waktu proses produksi pada pabrik perbaikankaroseri ini yang akan meningkatkan angka pemenuhan permintaan.ABSTRACTThis research aims to propose improvements for achieving thedemand for carrosserie repair for a transportation company in Indonesia. Thefocus of this research is about the backlog of demand from its carrosserie repairfactory in one of the transportion company in Indonesia. This company has 9pools which are spread throughout Jakarta and West Java, the demand came fromthese pools this is why the level of demand is high and the reason that this factoryneeds an improvement to fulfill its demand. DMAIC (Define, Measure, Analyze,Improve, and Control) is the method used in this research, in order to get the bestoutput that is going to be implemented in this company. Painting process is goingto be the focus of this research, painting process is separated into six big subactivitieswhich are metal cleansing, primer efoxy, putty, painting, and finishing.The improvements that are going to be made is going to have impact on itsproduction process duration which will lead to fulfillment of this company?sdemand.;This research aims to propose improvements for achieving thedemand for carrosserie repair for a transportation company in Indonesia. Thefocus of this research is about the backlog of demand from its carrosserie repairfactory in one of the transportion company in Indonesia. This company has 9pools which are spread throughout Jakarta and West Java, the demand came fromthese pools this is why the level of demand is high and the reason that this factoryneeds an improvement to fulfill its demand. DMAIC (Define, Measure, Analyze,Improve, and Control) is the method used in this research, in order to get the bestoutput that is going to be implemented in this company. Painting process is goingto be the focus of this research, painting process is separated into six big subactivitieswhich are metal cleansing, primer efoxy, putty, painting, and finishing.The improvements that are going to be made is going to have impact on itsproduction process duration which will lead to fulfillment of this company?sdemand.;This research aims to propose improvements for achieving thedemand for carrosserie repair for a transportation company in Indonesia. Thefocus of this research is about the backlog of demand from its carrosserie repairfactory in one of the transportion company in Indonesia. This company has 9pools which are spread throughout Jakarta and West Java, the demand came fromthese pools this is why the level of demand is high and the reason that this factoryneeds an improvement to fulfill its demand. DMAIC (Define, Measure, Analyze,Improve, and Control) is the method used in this research, in order to get the bestoutput that is going to be implemented in this company. Painting process is goingto be the focus of this research, painting process is separated into six big subactivitieswhich are metal cleansing, primer efoxy, putty, painting, and finishing.The improvements that are going to be made is going to have impact on itsproduction process duration which will lead to fulfillment of this company?sdemand., This research aims to propose improvements for achieving thedemand for carrosserie repair for a transportation company in Indonesia. Thefocus of this research is about the backlog of demand from its carrosserie repairfactory in one of the transportion company in Indonesia. This company has 9pools which are spread throughout Jakarta and West Java, the demand came fromthese pools this is why the level of demand is high and the reason that this factoryneeds an improvement to fulfill its demand. DMAIC (Define, Measure, Analyze,Improve, and Control) is the method used in this research, in order to get the bestoutput that is going to be implemented in this company. Painting process is goingto be the focus of this research, painting process is separated into six big subactivitieswhich are metal cleansing, primer efoxy, putty, painting, and finishing.The improvements that are going to be made is going to have impact on itsproduction process duration which will lead to fulfillment of this company’sdemand.]"