Penurunan Cacat Produksi Kaos Menggunakan Metode Plan – Do – Check – Action (PDCA) untuk Meningkatkan Kualitas Produk pada UMKM KENHO
DOI:
https://doi.org/10.71417/jca.v3i2.2377Keywords:
Defect, PDCA, Fishbone, 5W+1H, FMEA, Standarisasi PerbaikanAbstract
Penelitian ini bertujuan untuk mengidentifikasi faktor penyebab utama defect produksi kaos serta menurunkan cacat produk pada UMKM KENHO. Metode yang digunakan dalam penelitian ini adalah Plan-Do-Check-Action (PDCA). Pada tahap Plan dilakukan identifikasi jenis defect menggunakan data historis dan diagram Pareto untuk menentukan defect yang paling dominan, kemudian dilanjutkan dengan diagram Fishbone untuk mengidentifikasi faktor penyebab defect. Selanjutnya, analisis Failure Mode and Effect Analysis (FMEA) digunakan untuk menentukan prioritas penyebab berdasarkan nilai Risk Priority Number (RPN). Hasil analisis FMEA menunjukkan bahwa operator kurang teliti dan mengalami kelelahan menjadi prioritas pertama dengan nilai RPN sebesar 320, diikuti kondisi jarum mesin dengan nilai RPN sebesar 240 dan pengaturan RPM mesin yang terlalu tinggi dengan nilai RPN sebesar 210. Pada tahap Do dilakukan analisis 5W+1H untuk merinci tindakan perbaikan yang kemudian diimplementasikan melalui briefing sebelum produksi, pemberian waktu istirahat 5–10 menit setiap 2 jam, pemeriksaan dan penggantian jarum mesin, serta pengaturan RPM mesin sesuai standar. Pada tahap Check dilakukan evaluasi terhadap hasil implementasi selama satu bulan dengan membandingkan tingkat defect sebelum dan setelah perbaikan. Hasil evaluasi menunjukkan bahwa tingkat defect kaos bolong menurun dari 4,1% sebelum implementasi menjadi 2,6% setelah implementasi, atau mengalami penurunan sebesar 1,5 poin persentase. Pada tahap Action, tindakan perbaikan yang telah diterapkan kemudian distandarisasikan melalui SOP dan pedoman kerja untuk mempertahankan hasil perbaikan serta mencegah terulangnya defect kaos bolong.
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