Mid Term - Sistem Kualita 200. Industrial Engineering Der «rtm.-1i- University of Indonesia Universitas indonesia Fasiltator ; Akhmad Hidayatno, Time: 6 Menit, Type of Exam : Closed Book except for Forms ‘Tals ~vam sheets consist of 5 pages wis on group of tasks at the page 5 Fiease solve the following case stu ‘Quadrapack Inc. (QU) is one of the surviving companies who produce bottle contdiners to ‘be used by other companies, sucly 23 drink or chemical companies, QI use primarily shake-to- wder manyiscturing concept which the production begins whenever an order is received and ustomized based on the customer cpecifications, However, there are some products that have ~iandardized form and size that allow’ them to use make-to-stock concept. QI also has 4 simple ‘quality policy: “Customer Satigfactio.s Through Continuous Improvement ts Our Concern)" Ql produce the bottle with the cap with various size and materials, from bottle fof drinks, ~harrpoo, cosmetics, drink cups, gallon water etc which are based on plastics, QI custome (PT Aneka Tirto Sukarto PT. Frasadil ‘ PT. indofarma Sejati PT. Manyun aje PT, Mintalona 3 are: Pi. F ayitno Margono PT. Samudra Atlantik Selahtera PT. Sukarti Mantili PT. Mintalana Of course, the quality policy has not been easily implemented, reflecting to the rdsults of + the Customer Satisfaction Survey, conducted in June - December 2007 in the Gallon Products, that shows unsatisfactory results to some of the elements measured in the survey: Diagram Lingkaran Rata-rata Penilaian Kualitas Produk e295% Chart Customer Satisfaction Survey The piechart results is still not satisfactory according to the Ql’s top management! This is ~mhen they hired you as a well known: world-class quality consultant to improve their quality standings, So you started by ideniffying, what defects to the Ql's customer has been experi¢neing in the tabel on the following pageTable of Jakarta’s Customer Comp laints June-September 2007 No] Customer ‘Tanggal | Kuantitas | Jenis Defect 1_| PT, Aneka Tirto Sukarto 12-Jun-07 | 45 | Tipis, Ketebalan Tidak rata 2_| PT. Ancka Tirto Sukarto 13-Jun-07_|"" 108 | Gallon Bocorrberlubang 3_| PT. Brasadil 14-Jun-07 |" 29 | Tipis, Ketebalan Tidak rata 4_| PT. Indofarma Sejati 15-Jun-07 [120 | Neck pee sh ‘5_| PT. Indofarma Sejati 16-Jun-07 [63 | Gallon Bocorberlubang (6_| PT. Indofarma Sejati 17-Jun-07 [29 | Tipis, Ketebalan Tidak rata 7_| PT. Manyun aje 18-Jun-07 | 26 | Print rontok | PT. Manyun aje ¢ 19-Jur07_| 69" | Botol Bengkok ‘9_| PT. Mintalana 20-Jun-07 | 119 | Tipis, Ketebalan Tidak rata 10_| PT. Mintalana 21-Juns07_| 79 | Botol Bengkok 11] PT, Mintalana ‘22-Jun-07 | 43 | Botol Bengkok 12_| PT. Brasadil ‘23-Jun-07_|62__| Neck pecah (13 [PT Brosadit 24-Jun-07 | 117 | Tipis, Ketebalan Tidak rate 14_| PT. Brasadil 25-Jun-07 |___97___| Botol Bengkok — 15_| PT. Prayitno Margono 26-Jun-07 | 36 | Botol Bengkoke 16 PT. Prayitno Margono 27-Jun-07_|__55 | Neck pecah 17_| PT. Samudra Atlantik Sejahtera 28-Jun-07 [101 | Gallon Bocorfberiubang 18_| PT. Samudra Atlantik Sejahtera 29-Jun-07, | 66 | Gallon Bocorfberiubang 19 | PT, Samudra Atlantik Sejahtera 30-Jun-07 | 93___| Tipis, Ketebalan Tidak rata 20_[ PT. Sukarti Mantii Ttul-07, 29___ | Kotor/oerdebu \ 21_[ PT. Sukarti Mantili 2Jul-07, 25 | Noda kuning dalam kemasan 22._| PT. Indofarma Sejatl 3-Jul-07 112 | Kotorerdebu 23_[ PT Indofarma Sejat Jul-07 TH | hipis, Ketebalan Tidak rata 24 | PT. Indofarma Sejati S-Jul-07 88 Botol Bengkok 25_| PT. Indofarma Sejati 6-Jul-07 S1__| Neck pecah 26 | PT. Ancka Tirto Sukarto T-Jul07 '82___| Botol Bengkok i 27_| PT. Aneka Tirto Sukarto $-Jul-07 ‘si | Gallon Bocor/berhubang 28_| PT. Brasadil 9-5ul-07 121 | Tipis, Ketebalan Tidak rata 29__| PT. Indofarma Sep 10-Jul-67_| "113 | Botol Bengkok 30_| PT Indofarma Sej U-Jul-07 Ti [Neck pecan 31_ [PT Indofarma Sejati 12-Jul-07 29 | Gallon Bocor?berlubang 32_| PT, Manyun sje i3-Ju-07 [113 | Tipis, Ketebalan Tidak rata 33_[ PT. Manyun aje 14-Jul-07 32 [ Neck pecah 34_[ PT. Mintalana 15-Jul-07 85 | Neck pecah 35_| PT. Mintalana 16-Jul-07 ‘82 | Tipis, Ketebalan Tidak rata 36_[ PT. Mintalana V7-Jul-07 35 | Tipis, Ketebalan Tidak rata. 37_[ PT. Brasadil 18-Jul-07_| 121 | Kotoctberdebu 38_| PT. Brasadil 19-Jul-07 88___| Gallon Bocor/berlubang 39” | PT. Brasadil 20-Jul-0738 | Tipis, Ketebalan Tidak rata 40_[ PT. Prayitno Margono 21-Jul-07 86s Neck pecah 41_| PT. Prayitno Margono 22-Jul-07_|~ 92 | Gallon Bocor/berlubar 42_| PT. Samudra Atlantik Sejahtera 23-Jul-07 74 Tips, Ketebalan Tidak rata 43_[ PT, Samudra Atiantik Sejahters. 24-Jul-07 71 | Tipis, Ketebalan Tidak rata 1 44_| PT, Samudra Atlantik Sejahtera 25-Jul-07 70 | Tipis, Ketebalan Tidak rata 45_| PT. Aneka Tirto Sukarto 26-Jul-07 37____| Gallon Bocor/berlubang 46_| PT. Aneka Tirto Sukarto 27-Jul-07 40 Print rontok 47_[ PT. Brasadit ‘28-Jul-07_| 119 | Gallon Bocor/berlubang 48_| PT. Indofarma Sejatt 29-Jul-07 _| 76 | Tipis, Ketebalan Tidak rata 49_[ PT. Indofarma Sejat 30-Jul-07 $3 | Kotorberdebu '30_| PT. Indofarma Sejati 31-Jul-07 ST Gallon Bocor/berlubang, $1_[ PT. Manyun aje T-Aug-07_| 112 | Botol Bengkok 52_| PT. Manyun aje, 2-Aug-07. 3B | Kotorberdebu“Noda kuning dalam kemusan Gallon Bocor/berlubang, Tipis, Ketebalan Tidak rata Tipis, Ketebalan Tidak rata] Neck pecah | Tipis, Ketebalan Tidak rata, “Tipis, Ketebalan Tidak rata Botol Bengkok ‘Tipis, Ketebalan Tidak rata ang. Galt Bocor/berlubang. Tipis, Ketebalan Tidak rata Pecah pada bottomeee eee ewer eecene With your keen eye and power of deduction (second only to the popular anime fictional ance Detective Conan), you have identified that there is still defective products pase through he quality contol systems. This probably due many factors, including: Quality and Productions Staff Negligence (Kélalaian) Passing the reject product unintentionally ‘Not much of work rotation to refresh the Methods of dimensional and fungsional product sampling Quality Staff Competence Quality Staff also handles operational work Production performance is not measured by the product quality The low culture of responsibility Inadequate light in the production floor Inadequate coordination between the production and quality department * Quality control activities is not monitored regularly Dimensions and functions measurement not Scheduled properly Pressure reliability test could damage the product The procedures of quality inspections is Minor defects is not reported a Inefficiency is still visible in the product siimpling The machines is getting too old i ‘ Of course, what would be a world-class qUglity consultant without further data analysis, lusing the latest gadget available with built-in GPS, HSPDA, 6 MP Camera, you obtain that there is a relationship between the time to press the plastic materials and the thickness of the botde kins. Below are the data with X is the time to press the plastic materials and Y is thickness of the bottle skins in mm, ‘You obtain that in avemge within a year the company produce 10.000/week of bottled plastics. The table below shown the defects in various category during 32 weeks of obgervation periods: ig 7 A So, Mr. Consultant you must know what to do with all the collection of tools|that you have, Pick a tool, use the form you design, measure it, and analyze the results using youk answer books, In the end of all the tools, create a short recommendation to Mr, Akhmad as the }bwner of the QI company on how to improve the quality of the product based on your analysis.