Perancangan Alat Potong Presisi Berbasis Poka-Yoke untuk Mengurangi Defect dan Meningkatkan Kinerja Kualitas Produksi Lonjoran Kayu Lantai

Misbach Munir; Wisma Soedarmadji

doi:10.35891/83ypmm48

Authors

Misbach Munir Universitas Yudharta Pasuruan
Wisma Soedarmadji Universitas Yudharta Pasuruan

DOI:

https://doi.org/10.35891/83ypmm48

Keywords:

DMAIC, Poka-Yoke, Quality, Six Sigma, Wood Flooring Beams

Abstract

Product quality is an important factor in increasing the competitiveness of manufacturing companies. CV. X, which produces wood flooring, faces the problem of defective products in the measurement and cutting process, especially product length discrepancies with the company's specifications. This condition causes rework, delivery delays, and increased production costs. This study aims to identify the factors causing product defects and design process improvements through the application of the Six Sigma method with the Poka-Yoke approach. The research method uses the DMAIC (Define, Measure, Analyze, Improve, Control) stage. In the Define stage, the dominant type of defect is product length discrepancy (C2) with a proportion of 93.7% of the total defects. The Measure stage shows an average Defects Per Million Opportunities (DPMO) value of 405,165 with a sigma level of 1.74. The process capability analysis produces a Cpm value of 0.11 and a Cpmk of 0, so the process is not yet able to meet the specified product length specifications. In the Analyze stage, a cause-and-effect diagram is used to identify the root causes of defects related to human factors, machines, methods, and the work environment. The Improve stage is carried out through the application of the Poka-Yoke concept by modifying the cutting tool and adding a base table equipped with a wood clamping system to improve the stability and precision of the cutting process. The improvement results show an increase in the sigma level from 1.74 to 3.31 and a decrease in the DPMO from 405,165 to 312,757. In addition, the number of defective products reported decreased from 415 units to 97 units or by 77.03%. The results of the study indicate that the integration of Six Sigma and Poka-Yoke can be used as a quality improvement approach to reduce defects and increase the stability of the cutting process of wooden floor joists.

References

Adiyatma, R., Huda, F., Rosanda, M. R., & Setiafindari, W. (2022). Analisa Pengendalian Kualitas untuk Mengurangi Jumlah Kecacatan Produk Kain Batik dengan Metode Six Sigma di UMKM Dea Modis Batik dan Jumputan. Jurnal Aplikasi Ilmu Teknik Industri (JAPTI), 3(2), 84-94.

Akbar, M. I., Utomo, D. S., & Gunawan, S. (2024). Analisis Pengendalian Risiko Kualitas Pada Produk Kayu Lapis Menggunakan Metode Six Sigma. JURNAL TEKNIK INDSTRI Учредители: Mulawarman University, 2(1), 1-14.

Ardhaneswari, P. P. N., Priambadi, I. G. N., & Setiawati, N. L. P. L. S. (2024). Pengendalian Kualitas Produk Teh di PT XYZ Menggunakan Pendekatan Six Sigma. Metode: Jurnal Teknik Industri, 10(2), 249-259.

Azizah, T. N., Hunusalela, Z. F., & Sinambela, S. (2024). Usulan Perbaikan Kualitas Pada Proses Produksi Tahu dengan Metode Six Sigma dan Poka Yoke. Teknoin, 29(1).

Girsang, D. E. H., & Arvianto, A. (2023). Pengendalian Kualitas Produk Crude Palm Oil (CPO) dengan Metode Six Sigma Melalui Pendekatan DMAIC (Studi Kasus PTPN II PKS Sawit Seberang). Industrial Engineering Online Journal, 12(3).

Ikhsan, M. F., Pusporini, P., & Rizqi, A. W. (2022). Analisis Pengendalian Kualitas Produk Flat Bar Dengan Metode Six Sigma Pada Pt. Jatim Taman Steel. JUSTI (Jurnal Sistem Dan Teknik Industri), 2 (3), 315.

Laela, K. N., Primasanti, Y., & Indriastiningsih, E. (2025). Pengendalian Kualitas Produk Paperbag Menggunakan Metode Six Sigma (Doctoral dissertation, Universitas Sahid Surakarta).

Salomon, L. L. (2025). Pengendalian Kualitas Kemasan Obat Pada Perusahaan Farmasi Menggunakan Metode Six Sigma, Poka Yoke Dan Kaizen. Jurnal Ilmiah Teknik Industri, 13(1), 10-19.

Sari, R. N., Nugroho, A. D., Islami, M. C., & Dewi, S. (2023). Pengendalian Kualitas Produksi Kerupuk Dengan Menggunakan Metode Six Sigma Pada Pabrik Kerupuk XYZ. Heuristic, 197-208.

Sugengriadi, R. M., Taufik, D. A., & Giawa, B. L. (2024). Perbaikan Proses Produksi pada Komponen Grid dengan Metode Define, Measure, Analyze, Improve, Control (DMAIC) dalam Upaya Meningkatkan Kualitas Produk di PT. Schutz Container Systems Indonesia. INFOTEX: Jurnal Ilmiah Bidang Ilmu Teknik, 3(1), 147-156.

Tarigan, T. G. R., & Purwanggono, B. (2022). Pengendalian Kualitas Produk Crude Palm Oil (CPO) Dengan Metode Six Sigma (Studi Kasus PT Supra Matra Abadi). Industrial Engineering Online Journal, 12(1).

Ukasyah, U., Andriani, A., & Putri, I. M. M. (2024). Pengendalian Kualitas Produk Jadi Menggunakan Metode Six Sigma pada Line Machining Body Cover Di PT XYZ. JURNAL TEKNIK INDUSTRI, 5(01), 28-39.