IMPROVING OF THE QUALITY CONTROL PROCESS IN TORSO ASSEMBLY AREA AT TOY MANUFACTURING

Abstract

This project has done based on the most defects in PT. X called as LBO (number of defect). PT. X has a several process and the critical process which gives a big contribution to LBO is Torso Assembly. PT. X has goal LBO of 1,000 Parts Per Million (PPM) and today the LBO is 2,066 PPM. In PT. X, there are two inspection called Lot Buy Off (LBO) and Open Package Inspection. Today Torso Assembly has rank third to LBO and first rank to OPI in the year January 2015 – July 2016. Because of that, Torso Assembly has chosen as the selected area of observation and the process inside will be assessed. Therefore, to reduce the defect and align the process with current condition, the Improvement was held. The improving of quality control process aims to reduce defect, review the form used and a reporting system using Business Process analysis, Document Flow Diagram, Data Flow Diagram and document and form analysis. The improvements are redesigning the Business Process, develop database using Macro Excel and standardize document and form. The results are LBO reduced by 18, 15 % from 2,066 to 1,691 and the time saving by 80%.