+-COVER

DEFECT ANALYSIS AND EVALUATION FOR GALVANIZED

IRON SHEET PRODUCT IN CONTINUES GALVANIZING LINE
USING SIX SIGMA OF QUALITY IMPROVEMENT PT. FUMIRA

Internship Report
Submitted to International Program
Faculty of Industrial Technology
in Partial Fulfillment of the Requirements for the degree of
Bachelor Industrial Engineering
Universitas Islam Indonesia

By
Muahamad Ridho Herman 14 522 388

INTERNATIONAL PROGRAM
DEPARTMENT OF INDUSTRIAL ENGINEERING
FACULTY OF INDUSTRIAL TECHNOLOGY
UNIVERSITAS ISLAM INDONESIA
YOGYAKARTA
2018

APPROVAL PAGE
 DEFECT ANALYSIS AND EVALUATION FOR GALVANIZED
IRON SHEET PRODUCT IN CONTINUES GALVANIZING LINE
USING SIX SIGMA OF QUALITY IMPROVEMENT PT. FUMIRA
Internship Report
Submitted to International Program
Department of Industrial Engineering
in Partial Fulfilment of the Requirements for the degree of
Sarjana Teknik Industri
Universitas Islam Indonesia
By
Muhamad Ridho Herman (14522388)
PT FUMIRA

KAV A-1 BEKASI FAJAR INDUSTRIAL ESTATE MM 2100 INDUSTRIAL TOWN

CIBITUNG BEKASI 17520
Start Date of Internship : Oktober 5st, 2017
End Date of Internship : November 5st, 2017
Report Date of Internship : Agustus 20th, 2018

© 2018
All rights reserved
The Author hereby grants Universitas Islam Indonesia permission to reproduce and
distribute in electronic paper or publications in whole or part

Date : Agustus 20th, 2018 Signature of Author :_______________________

Certified by:
Date: ________________
Accepted by:
Date: ________________
______________________________________________
Dr.Eng, Ir. Rudi Suhradi Rachmat M.Eng
Supervisor
______________________________________________
Muhammad Ridwan Andi Purnomo S.T., M.SC., Ph.D.
Head of Industrial Engineering Department
 TABLE OF CONTENT
COVER ............................................................................................................................. i
APPROVAL PAGE ........................................................................................................ ii
CHAPTER I .................................................................................................................... 1
INTRODUCTION .......................................................................................................... 1
1.1 Background of Internship Program .................................................................... 1
1.2 Internship Objectives ......................................................................................... 7
1.3 Problem Limitation ............................................................................................ 4
1.4 Significances of the Internship Program ............................................................ 4
CHAPTER II: PROFILE COMPANY......................................................................... 6
PROFILE COMPANY................................................................................................... 6
2.1 Name of Company ............................................................................................. 6
2.2 History of PT. Fumira ......................................................................................... 6
2.3 Location.............................................................................................................. 7
2.4 Vision and Mission ............................................................................................ 7
2.5 Product .................................................................................................................... 6
CHAPTER III ................................................................................................................. 9
INDUSTRIAL DESCRIPTION .................................................................................... 9
3.1. Systems and Production Management ............................................................... 9
3.1.1. Company Layout......................................................................................... 9
3.1.2. Production planning .................................................................................. 11
3.1.3. Raw material ............................................................................................. 11
3.1.4. Warehousing ............................................................................................. 11
3.1.5. Material Planning ...................................................................................... 12
3.1.6. Engines Maintenance Management .......................................................... 12
3.2. Systems and Production Processing ................................................................. 13
3.2.1. Introduction ............................................................................................... 13
3.2.2. Line Process PT. FUMIRA ....................................................................... 13
3.3. Human Capital Management............................................................................ 29
3.3.1. Organizational structure ............................................................................ 29
3.3.2. Recruitment process .................................................................................. 31
3.3.3. Performance Appraisal ............................................................................. 31
3.3.4. Employee welfare ..................................................................................... 32
3.3.5. Working time ............................................................................................ 33
3.3.6. Payroll ....................................................................................................... 34
3.3.7. Occupational Health and Safety (K3) ....................................................... 34
 3.4 Marketing and Distribution .............................................................................. 35
3.4.1. Product ...................................................................................................... 35
3.4.2. Price .......................................................................................................... 35
3.4.3. Promotion.................................................................................................. 35
3.4.4. Place .......................................................................................................... 35
3.5 Management information System .................................................................... 36
CHAPTER IV: SPECIAL TASK ................................................................................ 36
SPECIAL TASK ........................................................................................................... 37
4.1 Background ...................................................................................................... 37
4.2 Research Limitation ......................................................................................... 37
4.3 Research Objective........................................................................................... 38
4.4 Research Methodology..................................................................................... 38
4.4.1 Quality ............................................................................................................ 38
4.4.2 Defect ............................................................................................................. 40
4.4.3 Detail Required Methods ............................................................................... 41
4.4.4 Data Collection............................................................................................... 42
4.4.5 Data Processing .............................................................................................. 44
CHAPTER V ................................................................................................................. 60
CONCLUSION AND SUGESTION ........................................................................... 60
5.1 Conclusion ........................................................................................................ 60
5.2 Suggestion ........................................................................................................ 60
REFERENCES ............................................................................................................. 62
 1

CHAPTER I

INTRODUCTION

1.1 Background of Internship Program

Students are the future generation that eventually will be the part of industry future
development. The ability and professionalism are not only fulfilled through the
college, but also have to be supported by the real work environment which can
broaden the students’ knowledge to be more familiar with the industry and the real
work. As the students, this internship is designated to provide opportunities for
students as a first step to experience real work environment.
Industrial Engineering is a part of engineering sciences which can be defined
as the profession in which a knowledge of the mathematical and natural sciences
gained by study, experience, and practice that are applied to develop ways to utilize,
economically, the materials and natural resources for the benefit of mankind.
Industrial Engineering has deeper orientation in constructing the process which
called process oriented. Moreover, it would be related with the process created in
order to repair the whole performance of a system which can be considered from
several sides, such as economy, quality assessment, impact toward environment, and
how all of those things giving benefit to human life.
The description about engineering has already been acquired by students
through courses and information during college. To raise the skill of students, this
implicit knowledge should be transformed into experiences or practical substance.
Then it will be externalized become the explicit knowledge to enroll the whole
process of knowledge management. International Program, Industrial Engineering
Department, Universitas Islam Indonesia realizes the importance of integrating both
theoretical and practical substances. Hence, an internship is held as a program which
combines academic skills with career-related work experience to form a link-and-
match education program between formal education and real-world problems.
Nowadays, industry is becoming more competitive. One of the biggest factor
is ASEAN Economic Community that already started in the end of 2015, which is
 2

last year. Moreover, Indonesia become one of the intended target for most of
industries all around ASEAN. To compete with other people from all around
ASEAN, it requires student who not only understand the theory that given in the class
by the lecturer, but also can implement the theories in the real cases.

The real cases can be observed from the real industry, which sometimes is a
bit different with the knowledge that already learnt. There are so many industries in
Indonesia, such as power industry, textile, manufacture, oil and gas, and also
services. To gain knowledge and see how the real cases that might occur in the real
industry, Universitas Islam Indonesia especially in Industrial Engineering
Department, requires the student to take internship, as one of the compulsory
subjects. This internship program aims to give the students experience of real work
environment. Besides, the student can know exactly how industry works, how the
industry maintains the production, procurement, inventory and its workers. This
program is a first step before later on face the real world of work. With this program,
hopefully, the students know and understand how real work looks like. Also, can
broaden, implement and complement the knowledge that already gained from the
university.

The construction industry sector has a strategic role to support economic

growth, improve the productivity of society, business creation, expansion of
employment, and poverty alleviation. Industrial sector become one source of
revenue prospective. Metal goods industry sectors contribute has its own prospects
for regional income. In 1999, there were 210 industries engaged in the manufacture
of metal goods, machinery and equipment are classified in the category of large and
medium industries, the output value of production is increasing every year. This is
because the metal material has a very long relative age compared to other materials
such as wood, so that the user becomes more economical material.
Demand for the material goods of metal, such as steel for construction, iron
for furniture, or other types of industries using these materials showed an increase.
Due to the impact of the economic crisis that began in 1997, making every sector
select materials that are considered able to survive for years in order to gain its
production output. Because of the maintenance is easier and cheaper, factors
associated with the increased production of technology and market demand, when
using the material of the metal material (steel).
 3

With the fact before, the need for products that can be prolong the age of the
material goods of metal to serve as the economic value of higher quality. Galvanized
industrial field is one of the supporters rather than the business. Because galvanizing
is the layer that makes the life of the material have metal goods becomes longer,
which is against the steel plating process so that it will hold from exposure to the
weather (corrosion) of up to 30-40 years. The purpose of making these products is to
support the needs of the industrial goods industry of metal (steel).

PT. FUMIRA is a business entity engaged in the industrial sector galvanized.

Products produced at the company is the roll of galvanized steel sheet and zinc
products with the kind of wave that is different.

Working through this practice students are expected to see, observe,

understand what was, and analyze the production process as well as other operational
activities carried out by PT. FUMIRA. By observing simultaneously implement these
activities are expected students are also able to find problems in the industrial world
or the world of work for the student's knowledge.

Galvanized iron sheet (GI) is material that important to fulfil customers

demand that required in developing country produce by PT. Fumira. High quality
product of GI that important to keep customers satisfaction because PT. Fumira
always produce high quality product with good quality control that always maintain
what customers need that want the best quality product.

1.2 Internship Objectives

From the background above, can be seen that there are several objectives that would be
achieved, such as:

a. To train the skills and attitudes in the real industry.

b. As one of character building for students to always be aware with the knowledge
and technology development, specifically in the way of establish the effective,
efficient, and innovative thought.

c. As the applicative process of study which in the form of direct observation to the
real practices in the real industry to know the concept, perception, and education.
 4

d. Be open minded toward new knowledge.

e. Synchronize the knowledge that already obtained from the university and
knowledge that observed from the real industry as the preparation for the real
work.

f. Being able to analyze the problems which appear in the industry and establish the
problem solving using the knowledge that is already acquired.

1.3 Problem Limitation

There are several limitations that implement, which are:

a. Observation and Collecting the Data, conducted in PT. Fumira, from Oktober 5th,
2017 until November 13th, 2017.
b. This problem that observed is only from two departments, which are Production,
Planning and Quality Control department and Continues Galvanized Line
Departement.

1.4 Significances of the Internship Program

There are several benefits that may get, not only for the student who joined the
internship but also for the university and company, such as:

1. For Student
a. Become experience for self-preparation of student to enter to field of work.
b. To learn and understand the flows, system, and work activity that are conducted
in the process of continues galvanized line.

c. To trial and test the skill for applying theoretical concept to practical aspects.
d. Learn the concept effective and efficient in the real case in industry.
e. The data collected will use to research for internship.

2. For University
a. To gain good relationship with company that the student done the internship.
 5

b. To get information for future student about internship preparation which

company that the student done the internship in.

3. For Company
a. To get some support or help from student in solving the problems that faced by
company.

b. To generate the knowledge of Industrial Technology, especially in Industrial

Engineering field.

c. Able to get new alternative hire worker, if the skill of student is needed by
company
 6

CHAPTER II

PROFILE COMPANY

2.1 Name of Company

Fumira is one of the largest producers of galvanized steel sheet in Indonesia. Fumira
was established in 1970 and the name of Fumira was came from the two first letter
of three shareholders, i.e. Fuji Steel (later, Fuji Steel merged with Yawata Steel to
become Nippon Steel), Mitsui Co. Ltd. and Ragam Logam (a subsidiary of Argo
Manunggal Group). Eventhough current Fumira’s share holders has changed, the
mission to provide high quality products and services are maintained.

Figure 2.1 Fumira's Logo

2.2 History of PT. Fumira

the first fumira’s factory was built in 1970 in Semarang, Central Java, producing
famous high-quality product of corrugated galvanized steel sheet (GI) branded moon
elephant. The second factory was built in 1997 in Bekasi, West Java. It was the first
factory in Indonesia which is using Continues Galvanized Line (CGL) with Non-
Oxidizing Furnace (NOF) system, technology of Nippon steel Corp. this system
produces an excellent zinc coating quality (lock forming quality) product, called
FUMIRAGRIP which has bendability to zero gap thickness without crack nor peeled
off. This coating quality is ideal for industrial use, particularly in automotive and
construction such as oil and air filters, car bodies, steel frames, partition, roof, siding
and deck.

As an innovative company, Fumira has succeeded in developing products color

coated galvanized steel sheet produced by the Color Coating Line from the draft
 7

Fumira in 1979. Based on the experience in operating the Color Line, Color Line
Continuous Fumira install modern in 2014 to increase production capacity and to
expand the types of products and quality.

Throughout the period of operation Fumira, many facilities have been held to
provide the best products and services to its customers such as, Shearing Lines,
corrugating machines, Slitting Line and Roll Forming machine into various shapes
of products. Now Fumira has become stronger and is always innovating to face the
transformation to meet customer needs and is committed to working with him as with
distributors and supplier.

2.3 Location
To maintain the company run their production, Fumira have factory, main office,
warehouse in same place in Kav. A-1 Bekasi Fajar Industrial Estate, MM2100
Industrial Town, Cibitung, Bekasi 17520 West Java, Indonesia. The location shown
in figure below

Figure 2.2 Fumira's Location

2.4 Vision and Mission

a. Vision

To become a producer of zinc coated galvanized steel sheet that famous in the world
and always maintain high quality product with services through continues
improvement.
 8

b. Mission

Produce high quality product with national standard has oriented to customer’s
satisfaction through continues improvement in quality and services with
implemented quality management ISO 9001:2015, Occupational Safety and Health
Management System OHSAS 18001:2007 and SNI 07-2053-2006, to get optimal
advantage and increasing the prosperity.

2.5 Product

The famous of product in Fumira is Galvanized steel sheet (GI) called FUMIRAGRIP
which has bendability to zero gap thickness without crack nor peeled off. This coating
quality is ideal for industrial use, particularly in automotive and construction such as
oil and air filters, car bodies, steel frames, partition, roof, siding and deck. PT. Fumira
located in Bekasi, West Java is a business unit engaged in the production of zinc-
coated steel. The resulting product is galvanized steel sheet and zinc products that
have a very good quality.

PT Fumira has developed a galvanized steel sheet product in accordance with

standard commercial specifications, drawings and structural. Fumira product brand
called FUMIRAGRIP that describe the quality of the zinc coating is the best (quality
lock forming) by being able to bend up to a gap of 0 (zero) thickness without peeling.
Tension rolled products Reel become back in the form of rolls and cut according to
the weight of customer needs.

Figure 2.3 Galvanized Steel Sheet (GI) CHAPTER III

 9

CHAPTER III

INDUSTRIAL DESCRIPTION

3.1. Systems and Production Management

3.1.1. Company Layout

3 4
37

36 33
- Compodek - B 832
34

- GG 750(new) - A.2 735 - 755 32 1

- F 714 - BL 710 35
- G 680 - I 600 - 610
31
- CLICK 33
- SF 750
- SF 650
- BL 600
- GP 550 30

28 5
27
26 2
25
17 29 6
24
23 22 7
13

8
18 19 20 21 12

14
11
9

10

16 15

Figure 3.1 Layout PT.FUMIRA

Information:

1. Office
2. Raw material warehouse
3. Security post
4. Motorcycle parking
5. Car parking
6. Clinic
7. tools Room
8. space Mechanics
 10

9. mosques
10. Electric Room
11. Engineering Room
12. Canteen
13. testing Room
14. garden
15. Continuous Production Line Area galvanized
16. testing Room CGL
17. Continuous Production Area Color Line
18. laboratory CCL
19. Shearing Line 5
20. Shearing Line 7
21. line Attachment
22. Shearing Line 6
23. slitter Line
24. laminating Line
25. slitter
26. bending
27. Packing Area 1
28. Packing Area 2
29. Area Pallets
30. CH04
31. CH03
32. CD02
33. CS01
34. Small Coil Line
35. Area Sheet
36. Forming Line
37. Truck Parking
 11

3.1.2. Production Planning

PT FUMIRA is a manufacturing company engaged in galvanized sheet steel. The company

has a production planning system by using treatise. PT. FUMIRA do production with the
system make to order. In the production planning process there are three parts that have roles
that Marketing, Sales Administration (SAD) and Production Planning Control (PPC).
Marketing part is the part that relates directly to the customer.

When marketing gets Product Order (PO), then immediately contact the Sales
Administration (SAD), in order of customer orders entered into the system that has been
integrated in the company. After ordering data entered into the system, Production Planning
Control (PPC) will begin to make a Schedule production called Work Order (WO). The
finished product is already in check otherwise salable quality and it will be submitted to the
warehouse department to give to the customer. Warehouse department will release the
product from the warehouse and called the delivery order (DO).

Figure 3.2 Flow process production system

3.1.3. Raw material

The raw materials used in producing Galvanize Iron is CRC (Cold Rolled Coil). CRC in the
process on the machine CGL (Continuous Galvanizing Line) into the GI. In addition to GI
production also in PT. FUMIRA producing GI color. The paint used on the CCL (Continuous
Color Line) uses 3 types of paint that is Polyester, Poly urethane and Polyvinylidene
Fluoride.

3.1.4. Warehousing

Warehousing PT FUMIRA carried out under the supervision of the warehouse department.
Warehouses in PT FUMIRA divided into 2 parts warehouse of raw materials (raw material)
 12

and the finished product warehouse (good finish). On the raw material warehouse containing
raw material (CRC), sub-materials (paint, Zinc, bonderite, parco, HCl) and spare parts.

Warehouse department PT FUMIRA using the FIFO (First In First Out) because less
land area and to avoid stock taking too much. Although the use of production systems make
to order but making unscheduled product from customers led to gudan become full.

3.1.5. Material Planning

Materials are raw materials or base materials in a production process. Material planning is a
concept in production management that addresses precisely the raw material requirements
planning is needed to be available as the already planned. In PT. FUMIRA material in the
warehouse will be in the data by the warehouse department and if it is approaching the
reorder point, the warehouse coordinate with the purchasing department to perform material
ordering. Raw materials used in PT. FUMIRA have done do supplier contract with the arrival
of raw material by the supplier.

3.1.6. Engines Maintenance Management

Maintenance management is the management of the maintain the work through a process of
planning, organizing and controlling the maintaining operation to provide the performance
of the industrial facilities. Their maintenance management aims to maintain the condition of
the equipment or machines that are used during the production process to allow for the use
of such equipment is always in optimum condition. In PT. FUMIRA there are three methods
of treatment.

1. Preventive Maintenance
This activity is carried out by a maintenance inspection by checking periodically /
regularly in accordance with a predetermined schedule. In the process of periodically
checking officers using special tools to detect irregularities in the process of checking
machine.
2. Corrective Maintenance
This activity is carried out by a mechanic if an error occurs on the machine when the
production cycle is running. The usefulness of this corrective maintenance in order to
 13

reduce errors that occur in the production process and reduce defects that would be caused
by poor machinery.
3. Workshop
This activity is carried out by mechanics by developing existing engines to get better. The
purpose of this activity is to promote and develop the machine.

3.2. Systems and Production Processing

3.2.1. Introduction
PT. FUMIRA process cold rolled coil steel according to the standard JIS G3141 and SNI 07-
3567-2006. The main raw materials for the supply by PT. Krakatau Steel is then entered into
the process of Continuous Galvanizing Line (CGL) of technology Nippon Steel Corp., Japan.
With the new technology, PT. FUMIRA produce Galvalume Iron (GI) with the advantages
of best in their market 0t (able to bend up to 180°, No cracks section folds) making it ideal
to meet the needs of industry, especially in the construction and automotive fields such as
steel frames, car bodies, partitions, roofs, walls and deck.

To meet the variety of products on the market, PT. FUMIRA innovating to produce
color-coated galvanized steel sheet which is derived from the Color Coating Line (CCL) by
using modern paint types such as polyester, polyurethane, polyvinylidene fluoride (PVDF)
which supply the paint company Deckert, Incote, and Akvo. Colour coat product has been
tested as a product that meets the requirements for use outside the tropical climate that
requires high resistance to color fading and damage so suitable for roofs and walls of
factories, offices, housing.

3.2.2. Line Process PT. FUMIRA

3.2.2.1 Continuous Galvanizing Lines Galvanizing Line (CGL)
CGL is a cold steel galvanizing process by coating with liquid zinc, aluminum and chromate
to avoid corrosion properties. Later in the CGL also made the establishment of material
properties with the furnace using direct combustion and radiation. CGL production process
is divided into three sections, namely Entry Section, Center Section, Delivery Section.
 14

1. Entry Section

Figure 3.3 CGL Entry Section

a. Pay Of Reel
The beginning of the production process is unrolled coil by inserting parts into the
Inner Diameter Mandrel which will rotate according to speed Delivery Line. Mandrel
maximum load is 20 tons, while the weight of the usual coil in production is 18 tons
- 15 tons. Some components in the POR, as snubber roll which serves to rotate the
coil to exclude a part of the head coil.

b. Entry Cut Shear

works using hydraulic cutting head dashes (CR) is of poor quality so that CR
production with good quality, but it cut the CR for quality test or quality check. Shear
Cut Entry consists of two blades were placed on the top and bottom. CR-cutting
process to proceed to the next process, namely welding.

c. Welder
To connect the head coil from POR 1 and POR 2, do the welding that the production
process is not interrupted. Welder machine uses electrical energy which is then
converted into heat energy through electrode and cathode. The welding process takes
14 seconds and when the welding process takes place the production line does not
stop. Not all sizes can be directly welded because there is an ideal material thickness
parameter do grafting. These parameters are divided into three categories of
thickness, group 1 (0.20 to 0.35), group 2 (0.35 to 0.50), group 3 (0.50 to 1.20).

d. Horizontal Loop Car Entry

 15

Entry Horizontal Loop function of Car is to accommodate the CR during the welding
process takes place because the production line must continue in order to further
process is not stalled.

2. Center Section

Figure 3.4 CGL Center Section I

Figure 3.5 CGL Center Section II

a. Annealing Furnace
Annealing Furnace CR is a combustion chamber with different temperatures in each
room, the goal is to improve the material properties to obtain the best quality material.
Furnace in the kitchen is divided into four spaces, namely:

b. Pre-Heating
CR heating process early stage, in order to raise CR temperature before entering into
the combustion chamber where the temperature is higher. In this PH space using
direct combustion with temperatures reaching ....

c. Non-Oxidizing Furnace
 16

In the space NOF, CR burned in directly with temperatures reaching 1200℃ with the
aim of eliminating the oxygen content contained in CR, so avoid the corrosion
process, but it can change the nature of the initial material is hard becomes soft so
we get the quality 0t (0 buckling or able to bend up to 180°, No cracks crease section)

d. Radiant Furnace
After the direct combustion, followed by radiation combustion heat generated from
the U-shaped pipes are placed at the bottom and top of the CR.

e. Slow Cooling
The cooling process starts from this space, to lower the temperature slowly CR used
heat elements of the electrical energy. A slow cooling process required in order not
to damage the material properties that are already in shape in the previous process.

f. Jet Cooling
Once the temperature lowered in the kitchen CR Slow Cooling, then continued
cooling in the kitchen CR Jet Cooling using the exhaust fan using the dumper
functioning open and close to produce heat.

g. Zinc Equipment
After the combustion process, then CR entered into Zinc Pot through Snot whose tip
directly into liquid zinc. Zinc function of this is to protect the outside of the CR in
order to avoid corrosion. Zinc is the temperature of 465℃,

h. Water Jet Wiping

To determine the thickness of the surface layer CR Zinc Air Jet Wiping use tool that
winds with high pressure so that the average thickness of the zinc can.

i. Water Jet Cooling

Initial cooling process after going through the Zinc Equipment by using the wind.

j. Water Spray
Process cooling, and proceed to the machine Water Spray, the cooling process in this
machine uses water that is sprayed directly to the CR so as to lower the temperature
reaches 40℃,

k. Skin Pass Mill

 17

This machine is used to get the smoother surface, it works similar to sanding, but the
difference in this SPM machine uses two roll given force (adjusted to the thickness
of the CR).

l. Skin Pass Mill Dryer

CR-shaped oven for drying of water due to the process using the SPM machines help
to avoid hot water. The drying process using hot steam from the boiling process
water.

m. Tension Leveler
Inside there are multiple roll machine that works in the opposite direction from the
position (position on pressing down, and vice versa). The purpose of this process is
to improve the visual quality of the defect and repair CR.

n. Chromate
To coat a layer of zinc, used to cover a layer of liquid zinc chromate which readily
react if GI met with the factors that cause corrosion and also closes the pores that
are not covered by Zinc.

o. Chromate Dryer
Serves to drain fluid CR of chromate by using steam from the boiling process water.

3. Delivery Section

Figure 3.6 CGL Delivery Section

a. Horizontal Loop Delivery Car
Serves to accommodate the CR when the cutting process for CR
 18

b. Delivery Cut Shear

Cut off the tail of the CR that are tailored to customer orders.

c. Frame Swing
Serves to form the first roll of CR so that the first roll and the tension has not occurred
colap (Inner Diameter could not bear the load of the roll)

3.2.2.2 Continuous Color Line (CCL)

CCL is a process of coloring technique on Galvanized within continue processing, which
means the process is running continuously from one machine to the last machine and
interconnected between one machine to another machine. The point here is related to the
engine if a problem occurs in one process, then this coloring will stop and must be reset back
to later be able to run again start all over again.

In CCL, there are three main parts in the production, i.e. there is Entry, Center, and Delivery.

1. Entry Section
Entry In this Section there are 7 process contained processes are:

a. Decoiler (Pay Of Reel 1 and Pay Of Reel 2)

Pay of reel or commonly called as POR is a machine that serves to put the GI
(Galvanized Iron) that is still shaped coil (Coil) and then drain GI (Galvanized Iron)
siphoned off to the next machine for processing.

The difference between POR 1 and POR 2 are not exist, they are the same
each has the same function, only the location of the two different positions, where
POR 1 is at the top, while POR 2 at the bottom. The placing is done so at the time of
POR 1 that coil rolls run out, it will proceed Coil is at POR 2, and also the opposite
if the current Coil on POR 2, then later Coil at POR 1 will continue to be the coloring
process is still running. Main Roll on POR capacity is 10,000 kg or 10 tons.

b. Entry Cut Shear

Entry cut shear a machine that serves to cut the coil. And after the cut, then the coil
then reconnected at the stitcher.
 19

An example is the time of trial new color, dummy coil will continue to spin
put on POR 1, while the GI coil, ready to color prepared on POR 2. Then the dummy
coil is cut, then connected with coil GI and GI coil is then cut again later coil
connected to the dummy, and then further process of trial can be done.

c. Stitcher
Stitcher is one of the machines in the CCL that serves to connect between the coil
existing at POR 1 with POR 2, or at POR 2 to POR 1. So, if the current coil at POR
1 has run out later to be joined with that of the POR Coil 2. To connect way is
positioned between the coil located on POR 1 or POR 2 in the middles of the stitcher
machine so didn’t miss. To position them manually by closing the bridle rollers
advance so that coil is not running, after bridle roller lowered then point the second
coil positioned on the middle of the stitcher machine, then after being in the right
position, connect the two coil with using the 2 punch.

The purpose of using two punch grafting is to make the connection that occurs
between the coil getting stronger. Typically for a stronger joint, added the base form
of plates at the same colored plate aims to distinguish between Sticher with coil. This
Sticher always do and didn’t to miss it, because if it does not disticher, the coil will
be broken when you sign in the next process, and may result in the process is repeated
from the beginning.

d. Accumulator Entry Loop

Accumulator Entry Loop a machine in the form of coil windings which amounts to
7 to the top, and 8 for the bottom which aims to help delay the process if the coil is
being spliced (Stitcher). To delayed this loop will run down by itself because the coil
remains pulled from delivery even though it was closed Bridle roll for the stitcher.
After disticher the line speed will be added later will loop back to its original position
around 95%.

e. Pre-Treatment
Pre-Treatment a machine that is useful to provide a layer of compounds called Parco.
Parco itself is a alkali powder which will be mixed with water to dissolve it, for the
dissolution of the composition is 5 pail Parco. Parco mixed with 1,800 liters of water.
Parco and the water temperature reach 60-70 °, Parco has a pH between 10-13, and
 20

to titrate between 25 - 45. The purpose for this is given Parco to clean the entire
surface of the coil. Parco itself is rarely used because only a few types of coil are
needed given Parco. Examples GI Unchromate, then galvalum, and the last at the
time of staining the PVDF.

f. Water Rinse 1 & 2

Water Rinse is a machine used for cleaning or rinsing fluid Parco attached to the coil
so that the coil becomes cleaner again. The way it works is sprayed (Spray). During
Parko is not used, then the Rinse Water is not used.

g. Chemical Coater
Chemical Coater almost the same as the Pre-Treatment is the same - just add
chemicals. However, the difference with Pre-Treatment is a liquid chemical named
in Chemical Coater Bondrite fluid. Bondrite fluid itself serves to coat the coil before
it is painted, and the purpose of this coating is that later on when in the paint, the
paint stick perfectly to the coil and is also durable.

For this bondrite own mix composition is a liquid bondrite in 20 liter was
mixed with 2 gallons of water, which each - each gallon of water has a volume of
about 19 liter. Therefore, it can be explained that this bondrite mixing ratio is 1: 2. 1
for liquid bondrite and 2 for a gallon of water.

h. Chemical Oven
Chemical Oven is a tool to heat so that the liquid is already dry Bondrite order not to
disrupt production activities. Of chemical oven temperature is 70 °.

2. Center Section
a. Coater
Once in the oven, then the next GI will do the coloring. In coloring is divided into 2
parts Coater 1 and Coater 2. In the coloring process, there are two Method coloring,
the first is forward (in the direction of the course coil), while the second is the method
of reverse (opposite direction to the direction of the course coil). For better quality
that using this reverse method for coloring can be more perfect.
 21

In this coater before do coloring, the first thing to do is to measure the

viscosity of paint. This viscosity using a cup measure that has been perforated and
then the cup was raised to the surface of the cup no longer immersed in the paint,
then calculate the second with a stopwatch. Calculations a second stop when the
drops of paint in the cup stop. And the viscosity is carried out every 30 minutes to
keep the viscosity of the paint itself.

b. Coater 1
Coater 1 This is a painting that is located on the 2nd floor and the coater 1 is the case
of painting for the first layer (Primary) and Back Coat. This painting is done by using
a roll, and there are two roll in the process of painting it. Roll 1 was called Roll Pick
Up function is to take the paint from a paint container which is then spun and the roll
2. To Roll 2 Roll calls are Applicator, its function is to process the removal of paint
from Roll 1 (Roll Pick Up) to roll 2 (Applicator ) then from Roll 2 will paint part of
the GI.

c. Oven 1
Oven 1 is a machine for drying paint primer and topcoat tub (cat back). In the oven
1 is divided into two zones which of each zone that has the same function, namely to
drain GI already coated by paint. For setting the temperature in each - each zone
adapted to the PMT (Peak Metal Temperature) of the GI. The heating in the oven is
done by means of ignition burner, then processed mixes with air, and air mix with
this fire will go into the oven through gratings. Lattice is like an iron lattice in the top
and bottom sides of the oven, then GI passing through the lattice.

d. Water Quench
Water quench is the machine to cool GI already in the oven before. The way it works
is to spray water on the GI will then before exiting the pinch roll tightly past the top
and bottom so that water remaining water quench none made it through to the next
process. After passing 2 roll tightly, then GI will be at the heater through tools such
as lattices before, so the possibility of water that through pass will be very small.

e. CPC 1
 22

CPC 1 is a tool that serves to straighten GI, so that GI is not skewed. For example, if
the GI tend to be skewed towards the WS, then the machine will steer towards the
DS to the sensor, in order to avoid the slope.

f. Marking
Marking This serve to provide the GI label to differentiate with other products. This
marking is set in semi-auto which means it will run its own stamp, but the setting
operator run. For the thickness and shape of the mold in accordance with consumer
demand.

g. Coater 2
Coater 2 is the same as Coater 1 only, at this second coater for painting the top (top).
This painting is done by using a roll, and there are two rolls in the process of painting
it. Roll 1 was called Roll Pick Up function is to take the paint from a paint container
which is then spun and the roll 2. To Roll 2 Roll calls are Applicator, its function is
to process the removal of paint from Roll 1 (Roll Pick Up) to roll 2 (Applicator) then
from Roll 2 will paint part of the GI. In Coater 2 also contained 2 Top Roll.

h. Oven 2
Oven 2 also has the same function with the oven 1, only that set-in oven 2 is divided
into 3 zones which for the temperature arrangement adapted to that PMT.

i. Water Quench 2
Water Quench 2 also has the same functionality as Water Quench 1.

j. CPC 2
CPC 2 also has the same function with CPC 1.

3. Delivery Section
a. Delivery Accumulator Loop
Delivery Accumulator Loop This has the same function with the entry accumulator
loop is to help delay the process if the coil is being cut for testing. To delayed this
loop will run upwards by itself because the coil is not withdrawn, but such is released
After the cut the line speed will be added later will loop back to its original position
around 10%.
 23

b. Delivery Cut Shear

Delivery cut shear This serves to cut the plate to be a part of testing by QC (Quality
Control), and then also to get rid of in case of defect, and also to cut stitcher
(connection plate).

c. Swing Arm
Swing Arm is shaped like a sleeve which serves to hold and rotate so that the coil
can be rolled up perfectly, if the coil is deemed perfect then this swing arm will return
to normal.

3.2.2.3 Finishing Line

In the next process there are several coils processed finishing section, namely cutting the coil
in accordance with the orders and also the formation of wave according to customer demand.
The stages in the process of finishing among others:

1. Process of Shearing Line 5 (SHL 5) → Corrugation (CH3)

A. The process SHL Machine Part 5
5 shearing machines in the finishing process is a useful machine for cutting steel plate
1 coil rolls into sheets of steel that have been measured according to customer wishes.
Here are some of the processes at the SHL5:

Mandrel

Figure 3.7 Process in Engineering SHL5

a. Mandrel
Coil laying place to do the cutting process with max. coil 5000 Kg

Table 3.1 Input Coil Hard

NPCN Coil GI4 - 35 773

Thick 0.2
Length (m) 3779
Wide 762
 24

Weight / 1:29
Meter
spec H

Table 3.2 Coil Input Soft

NPCN Coil GI4 - 26 094

Thick 0:45
Length (m) 444
Weight (Kg) 2145
Weight / 4.83
Meter
spec S

b. Levelers
Serve as a way to flatten the sheet plate.
hard: In the type of hard, not too use levelers section of the settings
soft: Keep the setting for the type of soft, according to the thickness of the coil
as follows:

Table 3.3 Parameter levelers spec. soft

Thick 0.2 0:25 0.3 0.4 0.5 0.6 0.7 0.8 1 1.1 1.2
E 16:30 15.80 16:45 16:25 16.60 16.80 16:50 16:40 16:00 15.80 15.90
D 16:35 15.80 15:50 15.60 16:10 16.60 16:50 16:40 16:00 15.90 15.90

c. Measuring Roll
Machines used to detect the required length, i.e. from the roll rotation which
measures the length required. For the engine speed at Spec Hard is about 70-80
mpm, while for the soft spec approximately 40-50 mpm.
d. Machine Cut (Cut Shear)
To cut according to the length that has been measured before.
e. Conveyor
On the conveyor are franking machine that serves to provide labeling on each
sheet using a sensor. There are several kinds of cap, namely:
ME = Moon Elephant SP = Swan Pyramid
CS = Crown Swan GP = Elephant Pyramid
 25

FG = Fumira Grip TC = Without Cap

ME Al-Zn = Moon Elephant (Galvalume) GB = Elephant Stand
f. Piller
Temporary shelters sheet cutting has been done according to the order, has a
capacity of max. 1000 pcs.

Table 3.4 Output in piller

Thick 0.2
Width (mm) 762
Diagonal 2265.02
Length (mm) 2133
spec H

B. The process Corrugation Machine (CH3)

Corrugation machine, there are several machines and one of them is CH3 in which a
machine to print or process the steel plate into the waves. CH3 shaped like a wave
on the image below:

Figure 3.7 Process in CH3

a. Input
Table 3.5 Input Machine Corrugation

Thick 0.2
Length (mm) 1829
Width (mm) 914
Weight (Kg) 1500 kg / lot
Weight / 1:29
Meter
spec H

At CH3 machine using a line speed with a speed of 40-50 mpm. The output of
the engine CH3 is divided into 2 lots of 500 pcs and 500 pcs and has a width
corresponding order as the table below.
 26

b. Output
Table 3.6 Output Machine Corrugation

Thick 0.2
Length (mm) 1829
Width (mm) 800
Weight (Kg) 1500 kg / lot
Weight / 1:29
Meter
spec H

Figure 3.8 The output waveform CH3

2. Laminating Process of Forming Line to Line

A. The process Laminating Machine Line
Line laminating machine is a machine that functions as a coil cutting machine with a
maximum length of 13m. Following the input to the output in machine Laminating
Line:

Guide Roll

Measure
Mandreel Conveyor Roll 2 Cut Shear Output
Roll

Figure 3.9 Laminating machines Process

a. Mandrel
Coil laying place to do heavy cutting process with max. 5000kg coil.
b. Measure roll
Machines used to detect the required length, i.e. from the roll rotation which
measures the length required.
c. Conveyor
 27

Has a function as the flow of goods from one place to the next, which is used in
industry to transport a product that his number of lots and sustainable.
d. Guide Roll
Where the laying of plastic in order to coat the zinc that will do the cutting.
e. Roll
Roll This serve to leveling after being coated plastic to stick strongly with its
zinc.
f. Cut Shear
The machine that serves as a tool to cut steel sheet in accordance with the size
of the order.
g. Shelter
Place the end of the cutting result sheets which have a maximum capacity is 5000
Kg.

B. Process in Forming Machine Line

Forming machine is an engine that converts the result sheet of the pieces in
laminating into waveforms that vary according to the type of the forming machine.
For the process of forming sheets shall be prepared in accordance with the order will
then be put to a forming machine in accordance with customer demand and then the
final outcome of these machines is the form of zinc that has been formed into waves.

Figure 3.10 The process in the machine forming

Examples of the resulting waveform forming machine:

a. L-700 machine

Figure 3.11 Waveform engine L-700

 28

Then there are the sizes of the standard on the machine L-700, as the table below:

Table 3.7 Standard Dimensions L-700

Standard
Dimensions
A = 720-725
B = 5-10
C = 55-56
D = 1-2
E = 18
F = 65-66
G = 42-43

b. GG-750 Machine

Figure 3.12 Wave machine GG-750

Then there are the sizes of the standard in GG-750 machine, as the table below:

Table 3.8 Standard Dimension GG-750

Standard
Dimensions
A = 745-750
B = 5-6
C = 1-2
D = 20-25
E = 22-25
F = 55-60
G = 55-60
H = 125
I = 160
J = 17
 29

3.3. Human Capital Management

3.3.1. Organizational structure
The organization is a means to support the achievement of a goal. With the organizational
structure will provide an explanation for the delegation of tasks and authority of the members
of the organization, thereby helping the smooth running of the organization's activities.

Broadly speaking, the organizational structure in PT. FUMIRA was divided into
several department such as the Ministry of Production, Ministry of HRD, Department of
Procurement, Warehouse Department, Sales & Marketing Department, the Department of
Finance & Accounting.

And here is the existing organizational structure in PT. FUMIRA:

 30

MANAGEMENT

FACTORY HEAD DIVISION EDP

BOARD OF DIRECTORS (BOD)
General Manager Manager Superintendent

EDP
Superintendent

Sales Admint
Manager

Finance & Accounting

Manager

Sales & Marketing Sales & Marketing

Team Leader Assistant Team Leader

Raw Material
Superintendnet

Ware House
Team Leader

Finish Goods
Superintendnet

Export & Import

Superintendent

BOARD OF Procurement Local Purchasing 1

General Manager
DIRECTORS Manager Superintendent

Local Purchasing 2
Management Advisor Superintendent
For F&A and Tax

Senior Finance
Controller
HRD&GA HRD&GA
Manager Superintendent
Management Representative
For Quality Management
System ISO

Management Representative CGL

For SNI Superintendent

Finishing Process
Superintendent

COLOR LINE
Superintendent

Factory Manager COLOR LINE

Manager Assistant

Mechanical Maintenance
Assistant

Mechanical Maintenance
Superintendent

Electrical Maintenance
Superintendent

Electrical Maintenance
Assistant

Quality Assurance
Superintendent

Figure 3.13 Organizational Structure PT. FUMIRA

 31

3.3.2. Recruitment process

In this process explains the recruitment conducted at PT. FUMIRA to meet the supply of
human resources, which refers to the Quality System Standard ISO 9001. This process is
done to implement and maintain a quality management system to look for employees with
direct employment relationship with the Company or with the Power Expert in accordance
with the needs of the Company / Organization.

And the following is the recruitment process flow at PT. FUMIRA:

Interview dengan Tehnikal Test &

Memilah Data Tes Kemampuan
Interview Awal Kepala Divisi Praktek
Calon Karyawan Dasar
Terkait Lapangan

Bekerja Dengan
Karyawan Tetap
Kontrak
Wawancara
Tes Kesehatan Tes Pskikotes
Akhir

Bekerja Dengan
Karyawan Tetap Masa Percobaan
3 Bulan

Figure 3.14 Employee Recruitment Process PT. FUMIRA

3.3.3. Performance Appraisal

The performance assessment is a process for employee performance achievement made by
the leader of the company systematically based on the work assigned to the employee. In the
assessment of the performance of employees of PT. This FUMIRA employees assessed that
all employees of PT. FUMIRA.

And to help the assessment process, there are three aspects that can become a reference
in the assessment process. These aspects are:

1. Aspects of Work
a. The quantity (amount of work that has been completed)
b. skill
c. Punctuality
 32

2. Aspects How it Works

a. Standard Operating Procedure
b. Acceptance of Orders
c. Usage Hours
3. Aspect Work Attitude
a. Leadership
b. Cleanliness
c. Order
d. Initiative
e. Spirit

3.3.4. Employee welfare

Some things are given PT. FUMIRA for Employees is as follows:

1. Employees Facilities
PT. FUMIRA provide transport facilities for Employees in the form of shuttle for the
return trip and go which is divided into several areas in Bekasi and surrounding areas,
the mosque for worship for Employees, lunch facilities are provided in the company
canteen and clinic facilities in the area of PT. FUMIRA.

2. Social Security
In accordance with the Constitution No. 11 of 2011 on the Social Security Agency and
the rules implementing it in the program as follows:
a. Social Security Health by the Social Security Agency of Health Contribution
borne:
 4% Wages charged to the Company
 1% Wage charged to workers
 Maximum wage as the basis for calculating fees is IDR 4.725.000
b. Social Security Employment by Labor Social Security Agency.
 Accident insurance
Fees borne by the Company of 0.89 x wages
 Old Age Security, the contributions borne by:
 33

o 3.7% x wages, charged to the Company

o 2% x wages, charged to workers.
 Life insurance
Fees borne by the Company amounted to 0.30% x wages
 pensions
o 2% x wages charged to the Company
o 1% x wages charged to Workers

3. Medical and Health Insurance

PT. FUMIRA provide treatment in the clinic in the area of Plant PT. FUMIRA. In
addition, PT. FUMIRA working with several hospitals around Bekasi for treatment of
its employees, including the RS. Siloam, RS. Hermina, RS. Family partners

3.3.5. Working time

The working time specified in the PT. FUMIRA in accordance with the laws that is for 40
hours of work in one week. PT. FUMIRA impose three kinds of working days, which is 5
working days, 6 days of work, and special working days guard. For the determination of
working time PT. FUMIRA is divided into 3 Shift.

Shift 1:

- Monday to Friday : 7:00 to 15:00 (Rest Hours 12:00 to 13:00)

- Saturday : 07:00 to 12:00 (Without Rest Hours)
Shift 2:

- Monday to Friday : 15:00 to 23:00 (Hours Break 7:00 p.m. to 8:00 p.m.)
- Saturday : 12:00 to 17:00 (Without Rest Hours)
Shift 3

- Monday to Friday : 23:00 to 7:00 a.m. (Rest Hours 4:00 to 5:00)

- Saturday : 17:00 to 22:00 (Without Rest Hours)
In that case the Company may changes certain terms of working time to achieve
productivity and efficiency.
 34

3.3.6. Payroll
The following are the components of payroll employees of PT. FUMIRA:

1. Wages Remain:
a. Basic wage
A basic wage base remuneration paid to workers according to the level or type of
work as stipulated by the agreement.

2. Variable Wages:
a. Premiums
Wages header is a premiums working hours is awarded each year automatically
and cumulative effect.
b. Incentive
Incentive pay is wages received by the employee beyond such basic salary,
overtime, bonuses THR, and bonuses - another bonus.
c. Overtime
Employees who perform overtime on Saturday and Sunday, and extra working
hours beyond schedule will be given overtime pay in accordance with the work
performed by the employee.
d. Bonus
The bonus earned each year, provided the value of KPI (Key Performance
Indicator) is reached, as well as good K3, meaning no work accidents in the
department.
e. THR (Idul Fitri)
Employees PT. FUMIRA holiday allowance is also given to provide several
times the base salary.

Components of fixed and variable wage stipulated by the Decree of the Board of
Directors considering financial conditions, the ability of the Company, and notified to the
Unions.

3.3.7. Occupational Health and Safety (K3)

Providing a safe working environment for workers. PT. FUMIRA K3 is considered, it is
proved by the provision of personal protective equipment such as helmets, gloves, masks. In
 35

addition, PT. FUMIRA held Safety Patrol held every day to reduce the occurrence of
accidents. In addition, there is a slogan in a lot factory related words of K3 from images, to
the slogan of 5S.

3.4 Marketing and Distribution

3.4.1. Product
Products produced by PT Fumira Jakarta is a galvanized steel sheet, plywood, color
galvanized steel sheet, galvanized sheet steel shaped and compo deck waves are packaged
using plastic. PT Fumira produce product with highest quality that can meet consumer
satisfaction and the Indonesian National Standard (SNI 07-2053-2006).

3.4.2. Price
Galvanized steel sheet products have a high price among competitors. But the price
according to the quality promised by the company. The price offered is varied in accordance
with the specifications. For specifications ranging zinc coated Rp48.000 / m - Rp170,000 /
m, for the specification of Color Coat ranging Rp64.000 / m - Rp186.000 / m and many other
price variations.

3.4.3. Promotion
To marketing the products, produce by PT Fumira, promotion is done by following an
exhibition held by INKINDO. Besides promotion is also done with a public lecture related
to property and construction.

3.4.4. Place
To distribution galvanized steel sheet products distributed through existing agencies in the
Region. Some agents are scattered in several cities in Sumatra, Java, Kalimantan, Papua and
Sulawesi.
 36

3.5 Management information System

A good information system in a company is a system that can integrate each element in the
company, ranging from consumer demand to the delivery of goods. Because if the company
is using the system integrate with each other which will provide benefits to the company in
the form of efficient use of time, secure data storage, accurate presenting data, and can reduce
data storage space.

PT FUMIRA engaged in galvalum industry since 1970 in Jakarta initially use

information systems AS / 400 of IBM products were made in 1987 to process data Mid-
range system. Then in the year 2000, PT FUMIRA does improvisation becomes more
modern information systems, through the Department of IT (Information Technology)
conducted a total modification of the system used and turned into FMSys (FUMIRA
System). In use, FMSys currently only used 30% because it is still in the development stage.
The integrated system includes Production Management, Stock Management and Sales
Distribution
 37

CHAPTER IV

SPECIAL TASK

4.1 Background

Galvanized steel sheet is very important product in Indonesia because so many

people need it not only for people but also for organization. Galvanized steel sheet
famous to use to build factory, house, office, apartment, bridge, fly over, etc. it’s only
just use for common use for building something but beside that this product also uses to
industrial use for instance in automotive, electronics, building, and equipment.
Galvanized steel sheet very needed especially in Indonesia because Indonesia one of
developing country in the world that really need galvanized steel sheet for develop the
country.

PT. Fumira Jakarta Factory one of manufacturer that produce galvanized steel
sheet in Indonesia with high quality product can fulfil the demand of customers in
Indonesia and others country. Fumira’s product especially galvanized steel sheet better
than competitor’s product because fumira has high quality product where the product
can be bending 0-T, it means galvanized steel sheet bending until 1800 without crack in
side of bending surface, it is very useful product when the product derivative to
industrial use, for forming, forging, and others because the bending of product until
1800.

4.2 Research Limitation

There are several limitations, such as:

1. Research is carried out in Manufacturing company that produce galvanized steel

sheet.
2. Factors as parameters in continues galvanizing line is control factors.
3. Defect data used from August 2017 until October 2017
4. Defect identification just based on standard defect in factory
 38

4.3 Research Objective

The objectives of this research are:

1. To know what the biggest defect in Continues galvanizing line

2. To know where the defect come from in Continues galvanizing line

3. The solution about defect in continues galvanizing line

4.4 Research Methodology

4.4.1 Quality
According to (Kotler, 2012) the meaning of product quality is "the ability of a product
to perform its functions, it includes the product's overall durability, reliability, precision,
ease of operation and repair, and other valued attributes" which means the ability of a
the product in its demonstration function, it includes overall durability, reliability,
accuracy, ease of operation and reparation of products as well as other product attributes
According to (Assauri, 1998): "Quality is the factors contained in a

goods or products according to the purpose for which the goods or products are intended
or required ".

According to (Tjiptono, 1997), Product Quality dimensions include:

1. Performance (performance), namely the principal operating characteristics of the

core product (core product) purchased.

2. Extra features (features), namely secondary or complementary characteristics

3. Reliability (reliability), which is less likely to be damaged or failed to use,

4. Durability, related to how long the product can continue to be used.

5. Compatibility with specification (conformance to specification) ie the extent to

which the characteristics of design and operation meet predefined standards.

6. Aesthetics (asthethic), the appeal of the product to the five senses.

The good quality according to the manufacturer is if the product produced by the
Company has been in accordance with the specifications as determined by the Company.
 39

While the quality is bad is if the resulting product does not comply with the specified
standard specifications and produce damaged products. However, companies in
determining product specifications should also pay attention to the wishes of consumers,
because without paying attention to products produced by the company will not be able
to compete with other companies that pay more attention to consumer needs. To create
a quality product in accordance with the wishes of consumers do not have to spend a
greater cost. Therefore, a good quality improvement program is needed, with the aim of
producing better, faster, and lower cost products (Latief, 2009).

Good quality according to the consumer's point of view is if the purchased product
is in accordance with the wishes, has benefits that match the needs and the equivalent
of the sacrifices issued by consumers. If the quality of the product cannot meet the wants
and needs of consumers, then they will regard it as a poor-quality product.

In general, the quality dimension according to (Gasperz, 2005) identifies eight quality
dimensions that can be used to analyze the quality characteristics of goods, as follows:

1. Performance

It deals with the functional aspects of the product and is a key characteristic that
customers consider when they want to buy a product.

2. Features

It is the second aspect of performance that adds to the basic functions associated with
choices and development.

3. Reliability

Associated with the possibility of a product perform its functions successfully within
a certain period of time under certain conditions.

4. Conformation

Relates to the level of conformity of the product to a predefined specification based

on the wishes of the customer.

5. Durability
 40

It is the lifespan of a product. This characteristic is related to the durability of the

product.

6. Service Capability

Is a characteristic related to speed, friendliness / modesty, competence, ease and

accuracy in the improvement.

7. Aesthetics

It is a subjective characteristic that is concerned with personal judgment and

reflection of individual preferences or preferences.

8. Perceived quality

Subjective, related to the customer's feelings in consuming the product.

4.4.2 Defect
According to (Mulyadi, 2005) defect is a product that does not have a predetermined
quality standard, but with the cost of rework to fix it, the product can economically be
refined back into a good product. According to (Bastian Bustami, 2006) defect is a
product produced from the production process, but not in accordance with the specified
quality specification.
The definition of defect according to PT.FUMIRA is the resulting product that is not
in accordance with predetermined quality standards and also not feasible to be
forwarded to the next process and can make consumers disappointed if later given to
consumers. Defects that occur in manufacturing companies can be caused by several
factors such as machine tools, methods (process / inspection), materials (raw,
consumable), man power, and work environment.
According to (Hidayat, 2012) the type of defect product (defect) is categorized into
two namely the defect function (major defect) and the defect (minor defect). The
classification of the defects is as follows:
1. Functional Defects (Major Defect)
Functional defects are defective because they do not meet the criteria for the
specification of the galvanized color product set by PT.FUMIRA
2. Defects (Minor Defect)
 41

A visual defect is a physical appearance of a product that is inconsistent with

expectations that may affect its use.

4.4.3 Detail Required Methods

4.4.3.1 Seven Tools Quality Improvement

There are seven basic quality tools, which can assist an organization for problem
solving and process improvements. The first guru who proposed seven basic tools
was Dr. Kaoru Ishikawa in 1968, that was concerned managing quality through
techniques and practices for Japanese firms. It was intended to be applied for self-
study, training of employees by foremen or in QC reading groups in Japan. valuable
resource when applying the seven basic tools. Seven Basic Tools of Quality Control:
The Appropriate Quality Techniques for Solving Quality Problems in the
Organizations. These seven basic quality control tools, which introduced by Dr.
Ishikawa, are: 1) Check sheets; 2) Graphs (Trend Analysis); 3) Histograms; 4) Pareto
charts; 5) Cause-and-effect diagrams; 6) Scatter diagrams; 7) Control charts.
(Catherine & Lau, 2015)

4.4.3.2 Pareto Chart

A Pareto chart, also called a Pareto distribution diagram, is a vertical bar graph in
which values are plotted in decreasing order of relative frequency from left to right.
Pareto charts are extremely useful for analyzing what problems need attention first
because the taller bars on the chart, which represent frequency, clearly illustrate
which variables have the greatest cumulative effect on a given system. The Pareto
chart provides a graphic depiction of the Pareto principle, a theory maintaining that
80% of the output in a given situation or system is produced by 20% of the input. The
Pareto chart is one of the seven basic tools of quality control. The independent
variables on the chart are shown on the horizontal axis and the dependent
variables are portrayed as the heights of bars. A point-to-point graph, which shows
the cumulative relative frequency, may be superimposed on the bar graph. Because
the values of the statistical variables are placed in order of relative frequency, the
graph clearly reveals which factors have the greatest impact and where attention is
likely to yield the greatest benefit.
 42

4.4.3.3 Fishbone Diagram

A fishbone diagram, also called a cause and effect diagram or Ishikawa diagram, is a
visualization tool for categorizing the potential causes of a problem in order to
identify its root causes. Dr. Kaoru Ishikawa, a Japanese quality control expert, is
credited with inventing the fishbone diagram to help employees avoid solutions that
merely address the symptoms of a much larger problem. A fishbone diagram is useful
in brainstorming sessions to focus conversation. After the group has brainstormed all
the possible causes for a problem, the facilitator helps the group to rate the potential
causes according to their level of importance and diagram a hierarchy. The design of
the diagram looks much like a skeleton of a fish. Fishbone diagrams are typically
worked right to left, with each large "bone" of the fish branching out to include
smaller bones containing more detail. Fishbone diagrams are used in the "analyze"
phase of Six Sigma’s DMAIC (define, measure, analyze, improve, control) approach
to problem solving. The range of time for do the forecasting in practice are varies.
Forecasting from the span of time point of view can be divided into 3 types, namely:
short-term, medium term and long-term forecasting (Santoso, 2009).

4.4.3.4 Control Chart

The control chart is a graph used to study how a process changes over time. Data are
plotted in time order. A control chart always has a central line for the average, an
upper line for the upper control limit and a lower line for the lower control limit.
These lines are determined from historical data. By comparing current data to these
lines, you can draw conclusions about whether the process variation is consistent (in
control) or is unpredictable (out of control, affected by special causes of variation).
Control charts for variable data are used in pairs. The top chart monitors the average,
or the centering of the distribution of data from the process. The bottom chart
monitors the range, or the width of the distribution. If your data were shots in target
practice, the average is where the shots are clustering, and the range is how tightly
they are clustered. Control charts for attribute data are used singly.

4.4.4 Data Collection

The type of data used in this study is the primary data which is data obtained from
PT. FUMIRA which became the place of research. The data obtained in this study
 43

are quantitative and qualitative data. Quantitative data in this research is data in the
form of numbers related to the production amount of continuous color line product
and also product data defect continuous galvanizing line product. Qualitative data in
this research is data in the form of written information, such as information about the
type of defective product, and the cause of the defect product.

This quantitative data is obtained from the document / archive of production and
the quality section. While the qualitative data obtained from interviews and
observations directly in the Company. The data used in this study is data obtained
during the period of August 2017 - October 2017.

In this chapter, there would be present the data that already gathered from the
library research. From the process in continues galvanizing line that already done
especially process in center section and delivery section, there are process in CGL
that has affect to quality of the galvanized steel sheet as a product from continues
galvanizing line which is in center section there are data that we need is temperature
data from Pre-heating, Non-Oxidizing Furnace, RTF, Slow cooling and Jet Cooling
before to get that data we need to record defect data in delivery section we get from
data library in August until October 2017.

Table 4.1 Defect Data from August to October 2017

Defect Weight Percentage

Serrated 16148 2%
Wavy 195245 28%
Garis ELC 18839 3%
Putih -Putih 87644 12%
Buckle 19468 3%
Under Thickness 8085 1%
Crack 7675 1%
Bolong 2013 0%
Dross Pick Up 9253 1%
Semi Hard 65266 9%
Line AJW 33967 5%
Dent 145 0%
Over Coating 2890 0%
Serrated 82426 12%
Scratch 10677 2%
Kumis 32713 5%
Under Width 76629 11%
 44

Kasar 2097 0%
Bercak Chromate 12875 2%
Telescope 18472 3%
Over Coating 4425 1%
Total 706952 100%

4.4.5 Data Processing

4.4.5.1 Defect Analysis Continues Galvanizing Line Product PT. FUMIRA

In this research, product defect analysis used is by using Six Sigma through the five stages
of analysis is define, measure, analyze, improve and control.

A. Define
Define is the stage of defining problems that occur in the product quality continuous
galvanizing line PT.FUMIRA. In the define phase of this research will define the product on
disability-based causes that have been sought when making observations. On the basis of the
existing problems, the highest 10 causes of defective products can be defined as follows:
Serrated, wavy, ELC line, putih-putih, buckle, under thickness, crack, bolong, dross pickup,
and semi hard.

1. Defining problems - problems related to quality standards or define the cause - the cause
of the defect. Of the 10 defect already described, the researchers conducted back to 5
defect filtering alone. This is done because of the 10 defects that have been described
only 5 are common in this galvanizing process. But for the presentation of data will still
be presented to - 10 data of the defect. 5 defects that often occur will be identified as
follows:

a) Wavy
This is a defect that often occur during the process of galvanizing. Wavy is a defect
because there is wavy in side of strip in coil. Most of this defect come from raw
material.
b) Serrated
This is one of the defects that often occur also in the process of galvanizing line, in
this defect there is serrated in side of strip on coil that one of defect in continues
galvanizing line.
c) Whites
 45

This is also one of the defects that often occur in the process of galvanizing line,
there is whites line in strip that come from the process in zinc coating in zinc pot
that affect from temperature cold or hot.
d) Mustaches
Mustaches is one of defect on galvanizing line, there is white bold spangle in side
strip that become defect in continues galvanizing line.
e) Buckle
Defect buckle, it is one of defect in continues galvanizing line process that affect
into quality of products because there is indentation when coil rolling.

2. Defining an action plan should be based on the observation and analysis of the study
are:
a) Repair and rejuvenation on the machine continuous galvanizing line
b) Improving the quality of the division of labor in particular continuous galvanizing
line
c) Closer scrutiny by appropriate methods
d) Work procedures clearer and more focused.
3. Establish goals and objectives of Six Sigma quality improvement based on the
observation: reduce or suppress product defects than originally 0.30% to 0%. As
evidenced by the presence of defective products the highest total of 0.33% and the
lowest was 0.01%. Based on the lowest percentage of actual division PT. FUMIRA
continuous galvanizing line can suppress the defective product to be 0%.
Based on the problems their defective products as previously described, defective
products can be harmful to the Company, therefore, the Company planned so that the defect
does not happen again.

B. Measurement
To conduct quality control to suppress the defective product statistically, the first step to do
is make a check sheet. The check sheet is useful to simplify the process of data collection
and analysis. Additionally, also check sheet is useful to know the problem areas based on
the types or causes and take the decision to make improvements or not. The following
production data for August - October 2017:
 46

Table 4.2 CGL Defect Data Period August – October 2017

Defectiv Defecti
e ve

Total type Disabilities Product Product

Mont Product Number Percent

h ion (Kg) age (%)

(Kg) Tele Mus Under Over

Serrat Wav Putih Buc Crac Scra
stac Thick Coat
ed y -Putih kle scop k tch
hes ness ing
e

Augus 925 1,20

760 1,420 1245 529 890 520 310 217 98 7198 0.77793
t 282 9
Septe 177.42 5,68 1,14 1,15 1,02
1,769 2,100 496 527 360 107 14 352 0.80890
mber 60 0 0 0 3
Octob 233775 4,76 2,90
7,820 1,078 863 318 201 139 195 54 18 335 0.78430
er 2 0 7
amou 503729 10 11 3,24 1,99 4,82 1,21
4,598 976 772 259 39 885 0.79179
nt 4 349 649 8 7 0 7
Avera 167909 3,88 1,08 1,60 0.79037
3,450 1,533 666 406 325 257 86 13 295
ge 8 3 3 7 5

From the table that has been shown, we can see the types of defects that often occur or
at most is wavy with the number of defects as much as 3883kg. The number of defects
serrated as 3450kg. Next is the white defects in the form as much as 1533kg. after that there
are as many types of disabilities Mustaches 1607kg. the number of defects buckle as much
as 1083kg. Then the next one is kind of defect Telescope as much as 666kg. The number of
defects Crack 406kg. amount of under thickness defects exist 325kg. The number of defects
exist 257kg scratch. The number of defects over coating there is 86kg.

In this measure phase measurement is divided into two stages:

1. Chart Analysis Control (P-Chart)

PT. FUMIRA the data used in this research that measured quality control of the amount
of the final product. Measurements were performed with the Statistical Quality Control
 47

Types P-Chart on the end product in the month of August 2017 - October 2017. The
following is the calculation of data P-Chart:
a. Calculate the mean (CL) or average - average final product
Calculations for the mean (CL) based on the formula in Equation 4.1, and get the
results as follows:
39885
𝐶𝐿 = = 0,007918
5037294

b. Calculating the percentage of Damage

Calculation of percentage of damage is based on the formula in Equation 4.2 and is
obtained as follows:
7198
 August : 𝑃 = 925282 = 0,007779
14352
 September : 𝑃 = 1774260 = 0,008089
18335
 October : 𝑃 = 2337752 = 0,007843

c. Calculating Control Over Limit or Upper Control Limit (UCL)

To calculate the control limits Upper or Upper Control Limit (UCL) is done based on
the formula in equation 4.3, and the obtained results of the calculation as follows:
0,007918 (1−0,007918)
 August : 𝑈𝐶𝐿 = 0,007918 + 3√ = 0,008194
925282

0,007918 (1−0,007918)
 September : 𝑈𝐶𝐿 = 0,007918 + 3√ = 0,008118
1774260

0,007918 (1−0,007918)
 October : 𝑈𝐶𝐿 = 0,007918 + 3√ = 0,008092
2337752

d. Calculating the Lower Control Limit or Lower Control Limit (LCL)

To calculate the lower control limit or LCL done on a formula in Equation 4.4 and
obtained the following results:
0,007918 (1−0,007918)
 August : 𝐿𝐶𝐿 = 0,007918 − 3√ = 0,007642
925282

0,007918 (1−0,007918)
 September : 𝐿𝐶𝐿 = 0,007918 − 3√ = 0,007718
1774260
 48

0,007918 (1−0,007918)
 October : 𝐿𝐶𝐿 = 0,007918 − 3√ = 0,007744
2337752

After getting CL, UCL, and LCL, then formed in the following table:

Table 4.3 Calculation results of proportion p, CL, UCL, and LCL

The
Total Total
NO proportion CL UCL LCL
Production Disability
p

1 925 282 7198 0.007779 0.007918 0.008194 0.007642

2 1774260 14352 0.008089 0.007918 0.008118 0.007718
3 2337752 18335 0.007843 0.007918 0.008092 0.007744
Total 5037294 39 885

From the calculation in table 4.2 above, then the next p control chart can be made as
follows:

p Chart Continues Galvanizing Line

0.008400
0.008200
0.008000
0.007800
0.007600
0.007400
0.007200
1 2 3

p UCL LCL Cl

Figure 4.1 Full map p

Based on the chart in the figure control can be seen that the data obtained entirely
within the control limits that have been set or no data that exceeds the UCL, and is less than
LCL. This shows that the control of damaged or defective products are classified as good,
but PT.FUMIRA need of repair to derive level of disability so as to achieve maximum value
in 0%.
 49

2. Stage Six Sigma level measurement and Defect Per Million Opportunities (DPMO)
To measure the Six Sigma level of production can be done in a way PT.FUMIRA
conducted by Gaspersz (2007: 42). The steps as follows:
a. Counting DPU (Defect Per Unit)
To measure defects per unit (DPU) based on the formula in Equation 4.5, and the
obtained results are as follows:
7198
 August : 𝐷𝑃𝑈 = 925282 = 0,007779
14532
 September : 𝐷𝑃𝑈 = 1774260 = 0,008089
18335
 October : 𝐷𝑃𝑈 = 2337752 = 0,007843

b. Calculate DPMO (Defect Per Million Opportunities)

To measure defects per million opportunities (DPMO) based on the formula in
Equation 4.6, and the obtained results are as follows:
7198
 August : 𝐷𝑃𝑀𝑂 = 925282 × 1.000.000 = 7779,25
14532
 September : 𝐷𝑃𝑀𝑂 = 1774260 × 1.000.000 = 8089,006
18335
 October : 𝐷𝑃𝑀𝑂 = 2337752 × 1.000.000 = 7843,005

c. DPMO Calculation Result convert to Table Six Sigma To Obtain Sigma Value
After getting the DPMO value every month, then the DPMO calculation results with
tables conversion six sigma to get sigma value. For the six-sigma table attached in
Appendix.
Here is the result of convection DPMO into Sigma Value:
 August : 𝐷𝑃𝑀𝑂 = 7779,25 ≈ 7779
𝑆𝑖𝑔𝑚𝑎 𝑉𝑎𝑙𝑢𝑒 = 3,92
 September : 𝐷𝑃𝑀𝑂 = 8089,006 ≈ 8089
𝑆𝑖𝑔𝑚𝑎 𝑉𝑎𝑙𝑢𝑒 = 3,91
 October : 𝐷𝑃𝑀𝑂 = 7843,005 ≈ 7843
𝑆𝑖𝑔𝑚𝑎 𝑉𝑎𝑙𝑢𝑒 = 3,92
 50

After doing the calculations DPU, DPMO and Sigma conversion value, it can be made
as the following table:

Table 4.4 Measurements degree to Sigma and Defect per Million Opportunities

Defective
Total Production SIGMA
Month Product DPU DPMO
(Kg) VALUE
Number (Kg)

August 925 282 7198 0.007779 7779.25 3.92

September 1774260 14352 0.008089 8089.006 3.91
October 2337752 18335 0.007843 7843.005 3.92
Amount 5037294 39 885 0.023711 23711.26 11.75
Average 1679098 13295 0.007904 7903.754 3.92

From the results of the calculations in the table above, production PT.FUMIRA has a
3.92 sigma level with possible damage in a million on 7904 production. This is certainly
becoming a very big loss if not treated properly, as more and more products that fail in the
production process must lead to swelling production costs and adverse to the Company.
C. Analyze
In analyze phase of this study using two methods analyze by using Pareto diagram and also
use the diagram cause - effect (Fishbone).

a. Pareto diagram
The data used in this Pareto diagram is data that is processed to determine the
percentage of products that are in decline. To measure using the following formula:

Equation 4.1 The formula to calculate the percentage of rejected products

𝑇𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑡𝑦𝑝𝑒 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡
% 𝐷𝑒𝑓𝑒𝑐𝑡 = × 100%
𝑇𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑎𝑙𝑙 𝑑𝑒𝑓𝑒𝑐𝑡

The percentage of rejected products:

10349
 Serrated: % Kerusakan = 39885 × 100% = 26%
11649
 Wavy: % Kerusakan = 39885 × 100% = 29%
4598
 White: % Kerusakan = 39885 × 100% = 12%
 51

And so on up to 10 or if any defect is formed just as the table below:

Table 4.5 Calculation of Pareto Diagram

%
Defect % DAMAGE
ACCUMULATION

Serrated 26% 26%

Wavy 29% 55%
White 12% 67%
Buckle 8% 75%
Telescope 5% 80%
Mustaches 12% 92%
Crack 3% 95%
Under Thickness 2% 97%
Scratch 2% 99%
Over coating 1% 100%

From the above calculation, then formed Pareto diagram as follows:

Figure 4.2 Pareto Chart

From Pareto diagram above, the cause of defect in continuous galvanizing line, there
is a wavy, serrated, white, mustaches, buckle, telescope, crack, under thickness,
scratch and over coating. The most significant cause in the process of continuous
galvanzing line is wavy a percentage of total disability is 29%. Other causes are
serrated, white, mustaches, buckle, telescope, crack, under thickness, scratch and
 52

over coating with the percentage of each 26%, 12%, 8%, 5%, 12%, 3%, 2 %, 2%,
1%. So, the repair can be accomplished by focusing on five types namely biggest
cause of disability wavy, serrated, white, mustaches, and buckle. This is because the
five types of disability, which occurred PT. FUMIRA in the period August 2017 -
October 2017.

b. Cause and Effect Diagram (Fishbone)

Causal diagram serves to show the relationship between the problems that occur with
possible reasons and factors that influence. The factors that affect and cause damage
to products in general can be classified as follows:
a) Man
The workers who perform work that is involved in the production process.
b) Material
Everything that is used by companies as a component of the product to be
manufactured, consisting of the main raw materials and auxiliary raw materials.
c) Machine
Machines and various equipment used in the production process
d) Method
Work instructions or work orders to be followed in the production process.
e) Environment
The circumstances surrounding companies that directly or indirectly affect the
company in general and specifically influence the production process.

After knowing the causes and factors that affect, and can be formed fishbone chart in
any defect such as the following:
 53

 Serrated

Figure 4.3 Serrated Fishbone Chart

a) factors Engineering
In this engine factors caused by:
 speed roll not exactly
b) Human factors
In this human factor caused by:
 Less scrupulous operators in setting speed roll
c) Material factors
In this material factors caused by:
 Material comes from supplier as raw material

 Wavy

Figure 4.4 Wavy Fishbone Chart

 54

Most of this defect come from raw material that affect to production in continues
galvanizing line.

 Putih – Putih (Whites)

Figure 4.5 White Fishbone Chart

a) factors Engineering
In this factor caused by:
 Temperature is too high
 Temperature between strip and Zn pot is not match
 Tension strip is to low or high
 speed roll and the line speed were not synchronous speed
b) Human factors
In this factor caused by:
 Lack of discipline in the operator checking machine settings
c) factor method
In this factor caused by:
 Roll speed setting that is not based on standard
d) Material factors
In this factor caused by:
 Zinc as a supporting material that not match in strip coating
 55

 Kumis (Mustaches)

Figure 4.6 Fishbone Chart Mustaches

a) factors machine
In this factor caused by:
 Speed is too low or high affect to tension sometimes strip touch the
subdesk side
 Air pressure is too high
 Temperature is too high or low
b) Human factors
In this factor caused by:
 Indiscipline to always check machine setting

 Buckle

Figure 4.7 Fishbone Chart Buckle

 56

a) factors Engineering
In this factor caused by:
 wrong setting about tension
b) Human factors
In this factor caused by:
 Lack of discipline in the operator checking machine settings
c) Material factors
In this factor caused by:
 Bad material from supplier
 The material out of control that affect to buckle as defect

D. Continuous Galvanizing Line Improvement

Improve an action plan will be made to carry out analysis of defects that occur on a
continuous galvanizing line and also to improve the quality of Six Sigma. After knowing the
cause of disability on continues galvanizing line, we then preparing a corrective action
recommendations or proposals which are prepared in general in an effort to reduce the level
of damage to the product as follows:

Table 4.6 Proposed Actions for Type Disabilities Serrated

Causative Normal
Element Proposed Corrective Action
factor standard

speed roll
Create checksheet to check the speed
speed roll must adjust
setting roll, and checked for ± 30
not exactly the line
minutes
speed
Machine Less Roll speed
scrupulous setting must
Checked roll speed and adjust the speed
operators in match the
line
setting line speed
speed roll settings
Decision
Raw material Brain power should determine about
Brain making to
according to choose good material from supplier that
Power use raw
the standard make our product become zero defect
material
Material Check raw material is it fulfil standard or
Material Material
should be not
has bad
fulfilling the
 57

Causative Normal
Element Proposed Corrective Action
factor standard

quality standard
product product of
Fumira

Table 4.7 Proposed Actions for Type Disabilities Wavy

Causative Normal
Element Proposed Corrective Action
factor standard

Raw material
GI material Checking the entry section, and
comes from
Material having no labeled if there are issues of
supplier has
problems material
wavy

Table 4.8 Proposed Actions for Type Disabilities Whites

Element Causative factor Normal standard Proposed Corrective Action

Oven Temperature in Regularly check the oven

temperature is accordance with temperature, Written in the form
too high the parameters of Check Sheet
Machine
speed roll and speed roll and Create checksheet to check the
the line speed is the line speed speed setting roll and line speed
out of sync synchronous and checked for ± 30 minutes

Lack of
Setting the
discipline in the
machine Routine checks related machines
Human operator
according to the and production equipment
checking
parameters
machine settings

Roll speed roll used

Checks on all parts of the
setting that is balanced
Machine existing roll on the machine
not according to between the WS
before and after production CCL
standards and DS
Supporting Zn mixture
Before, processing and after
Material material about always fulfil the
process always check the Zn pot.
Zn mixture standard
 58

Table 4.9 Proposed Actions for Type Disabilities Mustaches

Normal
Element Causative factor Proposed Corrective Action
standard

Oven Temperature Regularly check the oven

Machine temperature is accordance temperature, Written in the form of
not right with PMT Check Sheet

Air pressure is Air pressure

Check the parameter about air
not match must match
pressure within 30 minutes in each
with the
process
production
Human Lack of
Setting the
discipline in the
machine Routine checks related machines
operator
according to and production equipment
checking
the parameters
machine settings

Table 4.10 Proposed Actions for Defect Type Buckle

Normal
Element Causative factor Proposed Corrective Action
standard

Tension setting Tension

Regularly check the oven
is not right appropriate
Engineering temperature, Written in the form
material
of Check Sheet
parameters
Lack of
discipline in the
Engine Create checksheet to check the
operator
Human settings must machine settings and check for ±
checking
fit standard 30 minutes
machine
settings
Before doing production material
Material
Bad material should be checked to know
Material should fulfil
from supplier material is good or not to do
the standard
production.
 59

E. Control
Control in this study is the stage of final analysis of six sigma research methods that are
useful to control or regulate in order to avoid further incidents or production of defective
products. Controlling shape performed in this study are as follows:

1. Perform maintenance and repair machines periodically continuous galvanizing line

2. To supervise the raw material (GI) to be produced
3. Registering the entire product record each day
4. Checking machinery and equipment to match the existing parameters
5. Report the results of the number of defects by type of product record to the supervisor
or the head of the Department of Continuous Galvanizing Line.
 60

CHAPTER V

CONCLUSION AND SUGESTION

5.1 Conclusion
After doing some research, the conclusions that can be drawn are:

1. Based on production data obtained from PT.FUMIRA unknown amount of production

in the period August 2017 - October 2017 amounted to 5,037,294 kg continuous
galvanizing line with a number of product defects that occur in the production month
period August 2017 - October 2017 amounted to 39 885 kg of product. Based on the
calculations have been done, PT.FUMIRA have sigma level of 3.92 with the possibility
of damages amounting to 7904 kg in one million production (DPMO). This is certainly
becoming a very big loss if not treated, as more and more products that fail in the
production process, it can lead to swelling production costs and create losses for the
Company.
2. Type - the type of damage or defect that occurs in the product continuous galvanizing
line is is wavy a percentage of total disability is 29%. Other causes are serrated, white,
mustaches, buckle, telescope, crack, under thickness, scratch and over coating with the
percentage of each 26%, 12%, 8%, 5%, 12%, 3%, 2 %, 2%, 1%. The cause of the
defect is caused by several factors such as humans, machines, materials, and methods.

5.2 Suggestion
1. for Companies
a. Six Sigma methods can be used as one method of doing continuous product defect
analysis galvanizing line as well as product quality control.
b. Companies need to make the identification process to determine the factors -
factors that cause a product defect. Once identified company needs to perform
calculations in order to determine the amount of product defect. After knowing
the product defect, the Company should conduct a step to avoid things like that
which can harm the Company
 61

2. For Further Research

a. Also, can compare with other methods in order to obtain a more accurate
calculation.
b. Analyzing more about product defects that may arise from the process of
continuous galvanizing line.
 62

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Fegeinbaum, A. V. (1992). Kendali Kualitas Terpadu. Jakarta: Erlangga.
Gaspersz, V. (2002). Pedoman Implementasi Six Sigma Terintegrasi dengan ISO
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Gasperz, V. (2005). Total Quality Management. Jakarta: PT. Gramedia Pustaka Umum.
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