Design of Production System Improvement to Increase Productivity with Quality Control Circle Approach
Perancangan Perbaikan Sistem Produksi Untuk Peningkatan Produktivitas Dengan Pendekatan Quality Control Circle
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(1) Muhammad Rayhan Rabbani Universitas Islam Indonesia
Indonesia
(2) * Agus Mansur
Universitas Islam Indonesia
Indonesia
(*) Corresponding Author
Abstract
The increase in population has an impact on increasing community needs, especially in Indonesian sugar commodities. PG XYZ is one of the sugar production companies in Indonesia that targets a milling capacity of 5,750 tth. PG XYZ faced high sugar reject, so it needed to be reprocessed which had an impact hampering factory productivity. Data from the 2022 milling season shows that rejected sugar is at 5.15% with a total loss of IDR 1,619,300 for each ton. Therefore, it’s necessary to minimize the occurrence of rejected sugar. This research focuses on increasing quality productivity using a series of Quality Control Groups with PDCA stages on manufacturing parts. Data were collected through a FMEA questionnaire. The results showed the obstacles were pol blotong > 2.5%, outputting A < 55%, HK drops > 32%, and sugar reject due to black spots > 1%. The improvement plan is carried out by separating and creating a new clean water line for the supply of vacuum pump coolant, procurement, and installation of stirrer pans. The implementation was carried out for D1/D2 vacuum pan which showed a decrease in reject sugar due to black spots by 182.90 tons or 0.13% with a total of Rp 296,164,764.
References
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Coccia, M. (2018). The Fishbone Diagram to Identify, Systematize and Analyze the Sources of General Purpose Technologies. Journal of Social and Administrative Sciences Vol 4, 291-303.
Dahniar, T. (2018). Analisa Movement Fuel Menggunakan Quality Control Circle (QCC) untuk Mengurangi NG No Connection di PT. INS. TEKNOLOGI Vol. 1.
Dinagaran, D., Balasubramanian, K. R., Sivapirakasam, S. P., & Gopanna, K. (2020). Workplace Safety Improvement Through Quality Control Circle Approach in Heavy Engineering Industry. Recent Advances in Mechanical Engineering.
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Liu, H.-C., You, J.-X., Li, P., & Su, Q. (2016). Failure Mode and Effect Analysis Under Uncertainty: An Integrated Multiple Criteria Decision Making Approach. IEEE Transaction o Reliablity Vol. 65, 1380-1392.
Liu, Y., & Lin, B. (2020). Aplplication of Quality Control Circle in the Treatment of Moderate Cancer Pain in Inpatients. Japanese Journal of Clinical Oncology.
Luo, T., Wu, C., & Duan, L. (2018). Fishbone Diagram and Risk Matrix Analysis Method and it's Application in Safety Assessment of Natural Gas Spherical Tank. Journal of Cleaner Production Vol. 174, 296-304.
Maguad, B. A. (2006). The Modern Quality Movement: Origins, Development and Trends. Total Quality Management & Business Excellence.
Martin Pech, D. V. (2018). Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity.
Nelfiyanti, Casban, & Ridwan. (2020). Decreasing Scratch Defects with QCC Methods on the Line Assembly Frame of the Motorcycle Unit in PT XYZ. Spektrum Industri Vol. 18, No. 2.
Okolie P. Chukwulozie Member, I. O. (2018). Quality and Productivity Management. Proceedings of the World Congress on Engineering and Computer Science.
Parwati, C. I., & Sakti, R. M. (2012). Pengendalian Kualitas Produk Cacat dengan Pendekatan Kaizen dan Analisis Masalah dengan Seven Tools. Prosiding Seminar Nasional Aplikasi Sains & Teknologi Periode III.
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Psychogios, A. G., & Priporas, C. V. (2007). Understanding Total Quality Management in Context: Qualitative Research on Managers Awareness of TQM Aspects in the Greek Service Industry. The Qualitative Report Vol. 12.
Purba, H., & Malia, I. (2019). Gugus Kendali Mutu. Jurnal Pendidikan dan Ilmu Kependidikan Vol 4.
Rezaei, F., Yarmohammadian, M., Haghshenas, A., Fallah, A., & Ferdosi, M. (2018). Revised Risk Priority Number in Failure Mode and Effect Analysis Model from the Perspective of Healthcare System. International Journal of Preventive Medicine.
Riadi, S., & Haryadi. (2020). Pengendalian Jumlah Cacat Produk Pada Proses Cutting dengan Metode Quality Control Circle (QCC) pada PT. Toyota Boshoku Indonesia (Tbina) . Journal Industrial Maanufacturing Vol. 5, No. 1, 57-70.
Romero, D., Gaiardelli, P., Powell, D., Wuest, T., & Thürer, M. (2019). Total Quality Management and Quality Circles. International Federation for Information Processing.
Sambodo, P., & Cahyana, A. S. (2022). Product Quality Control in CV. XYZ Using Seven Tools and Quality Control Circle. Procedia of Engineering and Life Science Vol 3.
Sayogi, A. D., Rimawan, E., Wahyudi, Marida, & Rabathi, S. R. (2021). Improving the Quality of Production Milk Can Ø 502 X 603 Using the Qcc (Quality Control Circle) in the Manufacturing Industry. International Journal of Innovative Science and Research Technology Vol. 6.
Setiawan, B., & Soediantono, D. (2022). Benefits of Quality Control Circle (QCC) and Proposed Applications in the Defense Industry: A Literature Review. International Journal of Social and Management Studies (IJOSMAS) Vol. 3 No. 4.
Shrivastava, N., & Jain, A. K. (2020). Quality Control Circle on Indian Manufacturing Industries to Improve Productivity. International Journal of Engineering Applied Sciences and Technology.
Syahrullah, Y., & Izza, M. R. (2021). Integrasi FMEA Dalam Penerapan Quality Control Circle (QCC) Untuk perbaikan Kualitas Proses Produksi Pada Mesin Tenun Rapier. Jurnal Rekaya Sistem Industri Vol. 6 No. 2.
Tambunan, S., Susilawati, A., & Yohanes. (2020). Application of Quality Control Circle Method in Crusher Knife Reconditioning Products (Case Study in PT. Andritz Pekanbaru). Journal of Ocean, Mechanical and Aerospace.
Utama, A. Y., Supriyatna, H., & Kusuma, R. P. (2020). Quality Control Analysis of Candy Wrapping . International Journal of Innovative Science and Research Technology Vol. 5.
Wang, L.-r., Wang, Y., Lou, Y., Li, Y., & Zhang, X.-g. (2013). The role of Quality Control Circles in Sustained Improvement of Medical Quality. SpringerPlus.
Wicaksono, D. L., & Syahrullah, Y. (2020). Perbaikan Kualitas Produk Pengecoran Logam Dengan Menggunakan Metode Quality Control Circle (QCC). Jurnal Teknik Industri HEURISTIC, Vol. 17 No. 1, 29-42.
Xu, D., Lv, W., Liu, Y., Yu, Z., Feng, Y., & Tang, J. (2020). Application of Quality Control Circle in Improving the Correct Implemetation Rate of Multiple Drug Resistant Organism Isolation Measures in ICU Medical Personel. American Journal of Nursing Science.
Yamada, T. T., Poltronieri, C. F., Gambi, L. N., & Gerolamo, M. C. (2013). Why Does the Implementation of Quality Management Practices Fail? A Qualitative Study of Barriers in Brazilian Companies. Procedia - Social and Behavioral Sciences 81.
Yazdi, M. (2019). Improving Failure Mode and Effect Analysis (FMEA) with Consideration of Uncertainty Handling as an Interactive Approach . International Journal on Interactive Design and Manufacturing , 441-458.
Zhang, D., Liao, M., Zhou, Y., & Lui, T. (2020). Quality control circle: a tool for enhancing perception of patient safety culture among hospital staff in Chinese hospitals. International Journal for Quality in Health Care.
Zhong, X., Xiao, L.-H., Wang, D.-L., Yang, S.-W., Mo, L.-F., He, L.-F., . . . Luo, X.-F. (2020). Impact of a Quality Control Circle (QCC) on the Incidence of Catheter-Associated Urinary Tract Infection: An Interrupted Time Series Analysis. Americal Journal of Infection Control.
Zonnenshain, A., & Kennet, R. (2020). QuaLITY 4.0--the Challenging Future of Quality Engineering. Quality Engineering.
And, D. W., & Sohal, A. S. (2008). Total Quality Management and Employes' Involvement: A Case Study of an Australian Organisation. Total Quality Management & Business Excellence.
Aprina, B., & Ruspendi. (2021). Design of Finished Goods Inspection Acceleration with QCC Method and Seven Tools to Increase Productivity. SINTEK JURNAL: Jurnal Ilmiah Teknik Mesin.
Asosiasi Gula Indonesia. (2020). Dinamika Pasar Gula Dunia. Retrieved from Asosiasi Gula Indonesia: https://asosiasigulaindonesia.org/dinamika-pasar-gula-dunia/
Attaqwa, Y., Saputra, W. S., & Khamal, A. M. (2021). Kerem Quality Control Using the Quality Control Circle (QCC) . International Journal of Computer and Information System (IJCIS).
Badan Pusat Statistik. (2022). Badan Pusat Statistik Indonesia. Retrieved from Laju Pertumbuhan Penduduk, 2020-2022: https://www.bps.go.id/indicator/12/1976/1/laju-pertumbuhan-penduduk.html
Badan Pusat Statistik. (2022). Impor Gula Menurut Negara Asal Utama, 2017-2021. Retrieved from Badan Pusat Statistik: https://www.bps.go.id/statictable/2019/02/14/2014/impor-gula-menurut-negara-asal-utama-2017-2021.html
Bajaj, S., Garg, R., & Sethi, M. (2018). Total Quality Management: a Critical Literature Review Using Pareto Analysis. International Journal of Productivity and Performance Management Vol. 67 No. 1, 128-154.
Chen, P., Yuan, T., Sun, Q., Jiang, L., Jiang, H., Zhu, Z., . . . Xu, A. (2016). Role of Quality Control Circle in Sustained Improvement of Hand Hygiene Compliance: an Observational Study in a Stomatology Hospital in Shandong, China. Antimicrobial Resistance and Infection Control.
Chiu, W.-H., Luong, C.-Q., & Chi, H.-R. (2018). Shedding light on hospital service failure: findings from Taiwanese medical QCC. Total Quality Management & Business Excellent.
Coccia, M. (2018). The Fishbone Diagram to Identify, Systematize and Analyze the Sources of General Purpose Technologies. Journal of Social and Administrative Sciences Vol 4, 291-303.
Dahniar, T. (2018). Analisa Movement Fuel Menggunakan Quality Control Circle (QCC) untuk Mengurangi NG No Connection di PT. INS. TEKNOLOGI Vol. 1.
Dinagaran, D., Balasubramanian, K. R., Sivapirakasam, S. P., & Gopanna, K. (2020). Workplace Safety Improvement Through Quality Control Circle Approach in Heavy Engineering Industry. Recent Advances in Mechanical Engineering.
Faiesal, Z., Hamzah, A., & Yusri. (2018). Short Review of QCC (Quality Control Circle) Implementation toward Productivity Improvement: Case Study. International Journal of Engineering Research & Technology (IJERT) Vol, 7.
Guzmán, B. R., Brun, A., & Domínguez, O. C. (2019). Quality Management as a Determinant Factor of Productivity . International Journal of Productivity and Performance Management.
Idris, I., Sari, R. A., Wulandari, & Uthumporn, U. (2016). Pengendalian Kuallitas Tempe dengan Metode Seven Tools. Jurnal Teknovasi Vol. 3.
Isniah, S., Purba, H. H., & Debora, F. (2020). Plan Do Check Action (PDCA) Method: literature review and research issues. Jurnal Sistem dan Manajemen Industri Vol 4.
Jagtap, M., & Teli, S. (2015). P-D-C-A Cylce As TQM Tool-Continous Improvement of Warranty. International Journal on Recent Technologies in Mechanical and Electrical Engineering (IJRMEE) Vol. 2.
Jingxian, F., Yang, L., Qiong, L., Hong, Q., Hedi, L., Jinglan, Z., . . . Yingying, S. (2020). Application of Quality Control Circle in Promoting the Use of Rubber Dams in the Root Canal Treatment of Primary Teeth. Hindawi BioMed Research International.
Kartika, H. (2017). Perbaikan Kualitas dengan Menggunakan Gugus Kendali Mutu. Jurnal Ilmu Teknik dan Komputer Vol 1.
Kementerian Perindustrian Republik Indonesia. (2021). Siaran Pers: Tinjau Pabrik Gula, Kemenperin: Sektor Kritikal Berperan Penting Pulihkan Ekonomi. Retrieved from Kementerian Perindustrian Republik Indonesia: https://kemenperin.go.id/artikel/22745/Tinjau-Pabrik-Gula,-Kemenperin:-Sektor-Kritikal-Berperan-Penting-Pulihkan-Ekonomi
Kementerian Perindustrian Republik Indonesia. (2022). Siaran Pers Tekan Gap Kebutuhan Gula Konsumsi, Kemenperin: Produksi Terus Digenjot. Retrieved from Kementerian Perindustrian Republik Indonesia: https://kemenperin.go.id/artikel/23444/Tekan-Gap-Kebutuhan-Gula-Konsumsi,-Kemenperin:-Produksi-Terus-Digenjot-
Liu, H., Heng, B., Li, X., Zhao, Y., Wang, H., & Liu, C. (2021). Application of Quality Control Circle in Improving the Succes Rate of Indwelling Needles in Patients. Proceedings of Anticancer Research Vlo. 5.
Liu, H.-C., You, J.-X., Li, P., & Su, Q. (2016). Failure Mode and Effect Analysis Under Uncertainty: An Integrated Multiple Criteria Decision Making Approach. IEEE Transaction o Reliablity Vol. 65, 1380-1392.
Liu, Y., & Lin, B. (2020). Aplplication of Quality Control Circle in the Treatment of Moderate Cancer Pain in Inpatients. Japanese Journal of Clinical Oncology.
Luo, T., Wu, C., & Duan, L. (2018). Fishbone Diagram and Risk Matrix Analysis Method and it's Application in Safety Assessment of Natural Gas Spherical Tank. Journal of Cleaner Production Vol. 174, 296-304.
Maguad, B. A. (2006). The Modern Quality Movement: Origins, Development and Trends. Total Quality Management & Business Excellence.
Martin Pech, D. V. (2018). Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity.
Nelfiyanti, Casban, & Ridwan. (2020). Decreasing Scratch Defects with QCC Methods on the Line Assembly Frame of the Motorcycle Unit in PT XYZ. Spektrum Industri Vol. 18, No. 2.
Okolie P. Chukwulozie Member, I. O. (2018). Quality and Productivity Management. Proceedings of the World Congress on Engineering and Computer Science.
Parwati, C. I., & Sakti, R. M. (2012). Pengendalian Kualitas Produk Cacat dengan Pendekatan Kaizen dan Analisis Masalah dengan Seven Tools. Prosiding Seminar Nasional Aplikasi Sains & Teknologi Periode III.
Portal Informasi Indonesia. (2022). Baca Artikel: Menuju Swasembada Gula 2024. Retrieved from Portal Informasi Indonesia: https://indonesia.go.id/kategori/editorial/5097/menuju-swasembada-gula-2024?lang=1
Psychogios, A. G., & Priporas, C. V. (2007). Understanding Total Quality Management in Context: Qualitative Research on Managers Awareness of TQM Aspects in the Greek Service Industry. The Qualitative Report Vol. 12.
Purba, H., & Malia, I. (2019). Gugus Kendali Mutu. Jurnal Pendidikan dan Ilmu Kependidikan Vol 4.
Rezaei, F., Yarmohammadian, M., Haghshenas, A., Fallah, A., & Ferdosi, M. (2018). Revised Risk Priority Number in Failure Mode and Effect Analysis Model from the Perspective of Healthcare System. International Journal of Preventive Medicine.
Riadi, S., & Haryadi. (2020). Pengendalian Jumlah Cacat Produk Pada Proses Cutting dengan Metode Quality Control Circle (QCC) pada PT. Toyota Boshoku Indonesia (Tbina) . Journal Industrial Maanufacturing Vol. 5, No. 1, 57-70.
Romero, D., Gaiardelli, P., Powell, D., Wuest, T., & Thürer, M. (2019). Total Quality Management and Quality Circles. International Federation for Information Processing.
Sambodo, P., & Cahyana, A. S. (2022). Product Quality Control in CV. XYZ Using Seven Tools and Quality Control Circle. Procedia of Engineering and Life Science Vol 3.
Sayogi, A. D., Rimawan, E., Wahyudi, Marida, & Rabathi, S. R. (2021). Improving the Quality of Production Milk Can Ø 502 X 603 Using the Qcc (Quality Control Circle) in the Manufacturing Industry. International Journal of Innovative Science and Research Technology Vol. 6.
Setiawan, B., & Soediantono, D. (2022). Benefits of Quality Control Circle (QCC) and Proposed Applications in the Defense Industry: A Literature Review. International Journal of Social and Management Studies (IJOSMAS) Vol. 3 No. 4.
Shrivastava, N., & Jain, A. K. (2020). Quality Control Circle on Indian Manufacturing Industries to Improve Productivity. International Journal of Engineering Applied Sciences and Technology.
Syahrullah, Y., & Izza, M. R. (2021). Integrasi FMEA Dalam Penerapan Quality Control Circle (QCC) Untuk perbaikan Kualitas Proses Produksi Pada Mesin Tenun Rapier. Jurnal Rekaya Sistem Industri Vol. 6 No. 2.
Tambunan, S., Susilawati, A., & Yohanes. (2020). Application of Quality Control Circle Method in Crusher Knife Reconditioning Products (Case Study in PT. Andritz Pekanbaru). Journal of Ocean, Mechanical and Aerospace.
Utama, A. Y., Supriyatna, H., & Kusuma, R. P. (2020). Quality Control Analysis of Candy Wrapping . International Journal of Innovative Science and Research Technology Vol. 5.
Wang, L.-r., Wang, Y., Lou, Y., Li, Y., & Zhang, X.-g. (2013). The role of Quality Control Circles in Sustained Improvement of Medical Quality. SpringerPlus.
Wicaksono, D. L., & Syahrullah, Y. (2020). Perbaikan Kualitas Produk Pengecoran Logam Dengan Menggunakan Metode Quality Control Circle (QCC). Jurnal Teknik Industri HEURISTIC, Vol. 17 No. 1, 29-42.
Xu, D., Lv, W., Liu, Y., Yu, Z., Feng, Y., & Tang, J. (2020). Application of Quality Control Circle in Improving the Correct Implemetation Rate of Multiple Drug Resistant Organism Isolation Measures in ICU Medical Personel. American Journal of Nursing Science.
Yamada, T. T., Poltronieri, C. F., Gambi, L. N., & Gerolamo, M. C. (2013). Why Does the Implementation of Quality Management Practices Fail? A Qualitative Study of Barriers in Brazilian Companies. Procedia - Social and Behavioral Sciences 81.
Yazdi, M. (2019). Improving Failure Mode and Effect Analysis (FMEA) with Consideration of Uncertainty Handling as an Interactive Approach . International Journal on Interactive Design and Manufacturing , 441-458.
Zhang, D., Liao, M., Zhou, Y., & Lui, T. (2020). Quality control circle: a tool for enhancing perception of patient safety culture among hospital staff in Chinese hospitals. International Journal for Quality in Health Care.
Zhong, X., Xiao, L.-H., Wang, D.-L., Yang, S.-W., Mo, L.-F., He, L.-F., . . . Luo, X.-F. (2020). Impact of a Quality Control Circle (QCC) on the Incidence of Catheter-Associated Urinary Tract Infection: An Interrupted Time Series Analysis. Americal Journal of Infection Control.
Zonnenshain, A., & Kennet, R. (2020). QuaLITY 4.0--the Challenging Future of Quality Engineering. Quality Engineering.
Published
2024-06-03
How to Cite
Rabbani, M. R., & Mansur, A. (2024). Design of Production System Improvement to Increase Productivity with Quality Control Circle Approach. PROZIMA (Productivity, Optimization and Manufacturing System Engineering), 8(1), 1-10. https://doi.org/10.21070/prozima.v8i1.1669
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Copyright (c) 2024 Muhammad Rayhan Rabbani, Agus Mansur
This work is licensed under a Creative Commons Attribution 4.0 International License.
