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UNDERGRADUATE PROGRAM
Manufacturing System Lab. Industrial Engineering Dept. 5th Semester 2017 - 2018
TITLE (MAX 14 WORDS)
AUTHOR(S)
4.
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Submission Date:
7 DECEMBER 2017
___ (Receivers Signature)
Class
X
TABLE OF CONTENTS
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CHAPTER 1
INTRODUCTION
1.1 Background
Small and medium enterprise (SME) business has been the main activity of
generating money for Indonesian community in this years. SME business also has been
one of the main concern of Indonesian government to be developed in order to elevate
the prosperity level of Indonesian citizen. Nowadays, there are so many types of SME
business that run by Indonesian, such as food business, handcraft business, and many
more. One of the rare SME Business on Indonesia is Hygiene product business. Hygiene
product SME business usually sell hygiene product such as soap, detergent, carbolic,
and many more. Writers have a chance to review one hygiene product business in
Surabaya, which is Alpha Kimia. Alpha Kimia located in Sidoarjo, on Brigjen Katamso
street No.85, Kepuhkiriman, Waru. Alpha Kimia has several products, such as
handsoap, detergent, softener, ironing aid product, and perfume. Writers have a chance
to review one of their product, which is handsoap.
There are so many aspect affecting the product output. We can mention, the raw
material of the product, the process of product making, the worker skills, and the last
but not the least is quality management aspect. Quality management aspect can be
divided into 3 main aspect, which are Quality Planning (QP), Quality Assurance (QA),
and Quality Control and Improvement (QC&I). Quality Planning is a sequence of action
to plan the quality that want to be implemented to the product, while Quality Assurance
have a close relation to the course of action to assure the quality that have been planned
is implemented into the product, and Quality Control and Improvement is a course of
activities to control the quality of the product and also improve the quality of the product
into the next level of quality standard. In this opportunity, writers try to analyze the
Quality Assurance (QA) aspect of Alpha Kimia. There are several ways to analyze
Quality Assurance system of a company, such as Kaizen, Malcolm Bridge, Total Quality
Management, ISO, and Six Sigma. Writers assigned Kaizen as the method to be use to
analyze the Quality Assurance (QA) of the company.
Kaizen comes from Japanese language that means continous improvement.
Kaizen has commonly used to analyze quality assurance of a company, and one of the
most succes application of Kaizen is on Toyota. Kaizen concept is simply to make
continous improvement in every aspect of the bussiness, which started by disenchant all
the worker on the company to have the same perception about quality assurance, that
can be started by the lowest level of the worker. Kaizen concept believe that all
improvement, even the minimum one, can lead into a big effect to the business. Writers
try to analyze the implementation of quality assurance in Alpha Kimia, whether they
have implement the Kaizen concept or not. Writers would also give some feedback and
suggestion for the business so they can improve their business in the future.
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1.2 Problem Formulation
The problem formulation that need to be answered after finsihing this assignment
is as follows.
1. How is the implementation of Quality Assurance (QA) on Alpha Kimia?
2. How is the Kaizen Quality Assurance implementation on Alpha Kimia?
3. What improvement can be made for Quality Assurance of Alpha Kimia?
1.3 Objectives
The objective that can be obtained after finishing this final projecy is as follows.
1. To know how to implement Quality Assurance on a business.
2. To know how to implement Kaizen Quality Assurance on a business.
3. To make improvement on Quality Assurance on a business.
1.4 Benefit
The benefit that can be obtained after finishing this final project can be divided
into two, which is benefit for the writers and benefit for Alpha Kimia, which are:
1.4.1 Benefits for Writers
The benefit that can be obtained for the writers by making this final
project is as follows:
1. Writers can know how to implement Quality Assurance on a
business.
2. Writers can know how to implement Kaizen Quality Assurance on a
business.
1.4.2 Benefit for Alpha Kimia
The Benefit that can be obtained for the Alpa Kimia from this final
project is as follows:
1. Alpha Kimia can have input in the form of suggestion in order to
improve their business process.
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CHAPTER 2
STUDY LITERATURE
In this chapter, the study literatures that are needed for this final project will be
explained. The study literature will cover the the theory about quality, quality system, quality
assurance and KAIZEN thoroughly.
2.1 Quality
The traditional definition of quality is based on the viewpoint that products and
services must meet the requirements of those who use them. In another words, quality
means fitness for use. But, those traditional definition is outdated now. There is a
modern definition of quality. Quality is inversely proportional to variability. It implies
that if the variability in the important characteristic of a product decreases, the quality
of the product increases.
Quality is also the customers' perception of the value of the suppliers' work
output. The process and human factor cant be separated, therefore when quality is built
into a product, it will generates emotions and feelings within those who have taken part
in its creation. High quality is not an added value; it is an essential basic requirement.
Quality does not only relate solely to the end products and services a Company provides
but also relates to the way the Company employees do their job and the work processes
they follow to produce products or services. The work processes should be as efficient
as possible and continually improving. Company employees constitute the most
important resource for improving quality. Each employee in all organizational units is
responsible for ensuring that their work processes are efficient and continually
improving. Top management should provide the training and an appropriate motivating
environment to foster teamwork both within and across organizational units for
employees to improve processes. Ultimately, everyone in a Company is responsible for
the quality of its products and services.
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Quality assurance is the responsibility of the quality assurance department. The
mission of a quality assurance department is to provide an effective and efficient quality
assurance system and counsel for the operational units. The quality assurance
department must be manned by an adequate number of dedicated and adequately
qualified and trained personnel with well-developed interpersonal skills. The well-
developed interpersonal skills will provide the quality assurance personnel with
persuasive, diplomatic, tactful and resilient qualities generally required of them. The
quality assurance department must operate independently from the operational units and
it must regularly perform quality review activities (self-inspection audits/internal audits)
to ensure compliance within operational units with Company quality standards, good
working practices [GxPs: current Good Manufacturing Practice (cGMP), Good
Laboratory Practice (GLP), GCP, etc.], and local, national, regional and international
legal, ethical and regulatory requirements.
2.4 KAIZEN
Kaizen is a lean manufacturing tool that improve quality, productivity, safety,
and workplace culture. It focuses on applying small, daily changes that results in major
improvement over time. The philosophy first appeared when several Japanese business,
shortly after World War II, embraced the idea that doing things the way theyve always
been done was a bad idea, especially when better options were available that would
make them more competitive. Inspired by western competitors and manufacturing
methods, Kaizen came to be synonymous with company wide efforts to improve upon
and intelligently streamline business practices and manufacturing methods while
simultaneously respecting the product, craft, or the people involved with making it. By
applicating Kaizen, there are several benefits that can be obtained. The benefits are as
follows:
Increased productivity
Improved quality
Better safety
Lower costs
Improved customer statisfaction
Improved communication and cooperation
Improced morale and employee statisfaction
Greater personal investment in the company among employee and
management
Kaizen works by reducing waste and eliminating work process that are overly
difficult. It has one simple principle: look at how things can be improved, improve them,
and then improve them again and again. It can be done by using Plan-Do-Check-Act
(PDCA) to apply continuous improvement cycle. It can also be done by using other lean
tools such as automation, kanban, 5S and TPM. As a lean business practice, Kaizen
succeds when all employees look for areas to improves and provide suggestions based
on their observation and experience. In order that Kaizen can be successfully done, the
continuous improvement that is done can be broken down into six steps, those are:
Standardize. Come up with a process for a specific activity thats repeatable
and organized.
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Measure. Examine whether the process is efficient using quanitifiable data.
Compare. Compare the measurements against requirements. Does this
prcess save time? Does it take too much time? Does it accomplish the
desired result?
Innovate. Search for new, better ways to do the same work or achieve the
same result. Look for smarter, more efficient routes to the same end goal
that boost productivity.
Standardize. Create repeatable, defined processes for those new, more
efficient activities.
Repeat. Go baack to step one and repeat again.
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CHAPTER 3
WORK METHODOLOGY
In this chapter, the flowchart of work methodology that is used in making this final
project will be shown and explained further.
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CHAPTER 4
ANALYSIS OF QUALITY ASSURANCE
In this chapter, the analysis of existing condition of Alpha Kimia related to the concept
of quality assurance and KAIZEN will be provided.
As you can see from the recipe, they actually have a quite well quality
assurance, but one things that might be disturbing is the fact that Alpha Kimia
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use interval for the recipe. One of the example is the amount of salt, it is written
that they use 10-30 gram of salt to make the handsoap. Writers think that this
might affect the quality of the product. There is a potency of misunderstanding
of the recipe. Eventhough the idea of the making a recipe is good, it would be
more perfect if it is completed with a detailed measurement for each of the
component, for example for making a handsoap use only 10 gram of salt, etc.
The other things that might affect the product quality is the procedure of product
making. As you can see from the figure that the procedure given on the recipe is
not clear enough, especially for someone that not familiar with the process of
soap making. It will decrease the speed of transfer knowledge between
employee. Moreover, when the employee of Alpha Kimia resign from the job,
and they take in a new employee, the process of adapting to the standard of the
company will be longer than having a good and clear recipe. As writers mention
before, there are some procedure that not clear enough to be understood. For
example, how is completely dissolved to be explained?. There are no brief
explanation about the standard of completely dissolved on Alpha Kimia. The
recipe also does not mention the tools used in the making of the product. Writers
think that this is also a main issue for the recipe that been used by Alpha Kimia.
It would be better if they gave the detail of equipment needed to make the
product, because in writers experience that the different tools will lead into
different process and output. For example, the writers already conduct the
practicum on handsoap making, at the first trial, writers try to use a big diameter
bucket, which the time needed to make the soap completely dissolved is way
longer than writers second trial, which used smaller diameter bucket. These type
of things might be the concern for Alpha Kimia to revised their recipe, so they
can improve their quality assurance system for their product, which gonna lead
into customer satisfaction and level up their business.
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CHAPTER 5
CONCLUSION AND SUGGESTION
In this chapter, the conclusions and suggestions that can be made after making the final
project will be explained.
5.1 Conclusions
In this subchapter, the conclusions of this final project will be explained. The
conclusions are as follows.
1. Alpha Kimia has already implement quality assurance in the form of recipe
for the produc and final checking.
2. There are some problems that found in Alpha Kimia quality assurance system,
which are the recipe is not completely clear and the final checking is still
using subjective measurement method for variable characteristic (viscosity).
3. Kaizen quality assurance can be implemented in Alpha Kimia in order to have
a better quality assurance system that will lead to better product quality.
5.2 Suggestions
In this subchapter, the suggestions that can be made by making this final project
will be explained. The suggestions are as follows.
1. For the recipe of the product, it should be completed with a detailed
measurement for each of the component, the clear procedure of product
making, and the detail of equipment needed.
2. For the final checking of the product, the company should have a proper test
for the viscosity test, such as by using viscometer. All of the members in
Alpha Kimia should have the same perception, especially on the production
section about the quality assurance.
3. Alpha Kimia should implement several simple Kaizen quality assurance
tools, such as 5S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke) and Kaizen
Report and/or Kaizen Suggestion Board
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REFERENCES
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