DAFTAR ISI

HALAMAN COVER ..................................................................................... i

LEMBAR PERSETUJUAN........................................................................... ii

HALAMAN PENGESAHAN......................................................................... iii

KATA PENGANTAR..................................................................................... iv

DAFTAR ISI.................................................................................................... vi

DAFTAR GAMBAR....................................................................................... x

DAFTAR TABEL........................................................................................... xv

DAFTAR RUMUS.......................................................................................... xx

DAFTAR LAMPIRAN................................................................................... xxi

BAB I PENDAHULUAN

1.1 Latar Belakang....................................................................I-1

1.2 Rumusan Masalah...............................................................I-2

1.3 Tujuan..................................................................................I-2

1.4 Manfaat................................................................................I-3

1.5 Batasan Masalah..................................................................I-3

1.6 Sistematika Penulisan..........................................................I-4

BAB II LANDASAN TEORI

2.1 Pengertian Bill Of Material (BOM).....................................II-1

2.2 Pengertian Standar Operasional Prosedur (SOP)................II-4

2.3 Fungsi dan Tujuan SOP.......................................................II-5

2.4 Tahap-tahap dalam Penyusunan SOP..................................II-5

2.4.1 Analisis Sistem dan Prosedur Kerja..........................II-5

2.4.2 Analisis Tugas...........................................................II-6

2.4.3 Analisis Prosedur Kerja............................................II-7

2.5 Prinsip Dasar Penyusunan SOP...........................................II-8

2.6 Pengertian Kanban..............................................................II-9

2.7 Persiapan Prakanban............................................................II-10

2.8 Aturan Kanban....................................................................II-11

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2.8.1 Jenis-jenis Kanban dalam Sistem JIT.......................II-12

2.9 Metode Pengukuran Kerja Secara Langsung......................II-13

2.9.1 Pengukuran Waktu Kerja dengan Jam Henti............II-13

2.9.1.1..............................................................Langka

h-langkah Sebelum Melakukan

Pengukuran Kerja........................................II-13

2.9.1.2..............................................................Melaku

kan Pengukuran Waktu Kerja.....................................................II-15

2.10 Penyesuaian.........................................................................II-17

2.10.1 Maksud Melakukan Penyesuaian............................II-17

2.10.2 WestingHouse System’s Rating................................II-18

2.11 Kelonggaran........................................................................II-19

2.11.1 Kelonggaran untuk Kebutuhan Pribadi...................II-21

2.11.2 Kelonggaran untuk Menghilangkan Rasa

Fatique......................................................................II-21

2.11.3 Kelonggaran untuk Hambatan Tak

Terhindarkan.............................................................II-21

2.12 Pengukuran Waktu Kerja dengan Sampling Kerja..............II-21

2.12.1 Langkah-langkah Melakukan Samping Kerja..........II-23

2.13 Assembly..............................................................................II-24

2.13.1 Assembly Line untuk Mencapai Low-Cost

Production.................................................................II-24

2.14 Peta-peta Kerja....................................................................II-25

2.14.1 Definisi Peta Kerja...................................................II-25

2.14.1.1............................................................Simbol

-simbol yang digunakan dalam

PetaKerja Keseluruhan................................II-26

2.14.1.2............................................................Peta

Kerja Keseluruhan II-28

2.14.1.3............................................................Peta

Kerja Setempat II-31

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2.15 Gerakan-gerakan Dasar yang diuraikan oleh Gilbreth........II-29

2.16 Definisi Line Balancing.......................................................II-36

2.16.1Metode RPW ............................................................II-38

2.16.2Metode LCR..............................................................II-39

2.16.3Metode Region Approach.........................................II-39

2.17 Pengendalian Mutu (Quality Control).................................II-40

2.18 Predetermined Time System................................................II-44

2.18.1Pengukuran Waktu Standar.......................................II-44

BABIII METODOLOGI PENELITIAN

3.1 Studi Literatur......................................................................III-2

3.2 Perumusan Masalah.............................................................III-2

3.3 Penetapan Tujuan................................................................III-2

3.4 Batasan Masalah..................................................................III-2

3.5 Pengumpulan Data..............................................................III-3

3.6 Pengolahan Data..................................................................III-3

3.6.1 Bill Of Material (BOM)...........................................III-3

3.6.2 Standard Operational Procedure (SOP)...................III-3

3.6.3 UjiStatistik...............................................................III-3

3.6.3.1 Uji Keseragaman Data...............................III-3

3.6.3.2 Uji Kecukupan Data..................................III-3

3.6.4 Perhitungan Waktu Siklus.......................................III-4

3.6.5 Perhitungan Waktu Normal.....................................III-4

3.6.5.1 Perhitungan Faktor Penyesuaian...............III-4

3.6.5.2 Perhitungan Faktor Kelonggaran...............III-5

3.6.6 Perhitungan Waktu Baku.........................................III-5

3.6.7 Perhitungan Work Sampling....................................III-5

3.6.7.1 Uji Kecukupan...........................................III-5

3.6.7.2 Menentukan Jumlah Tenaga Kerja

Berdasarkan Waktu Standar......................III-5

3.6.8 Peta-Peta Kerja........................................................III-6

3.6.8.1 Peta Proses Operasi...................................III-6

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3.6.8.2 Assembly Chart..........................................III-6

3.6.8.3 Peta Aliran Proses......................................III-6

3.6.8.4 Diagram Aliran..........................................III-6

3.6.8.5 Peta Tangan Kiri dan Tangan Kanan.........III-6

3.6.9 Line Balancing.........................................................III-7

3.6.9.1 Metode Ranked Positional Weight

Technique...........................................III-7

3.6.9.2 Metode Largest Candidate

Rule (LCR).........................................III-7

3.6.9.3 Metode Region Appoach (RA)...........III-7

3.6.10 Quality Control...................................................III-8

3.6.10.1 Check Sheet........................................III-8

3.6.10.2 Histogram...........................................III-8

3.6.10.3 Diagram Pareto...................................III-8

3.6.10.4 Diagram Fishbone..............................III-8

3.6.11 Predetermined Time Standard...............................III-9

3.6.11.1 Peta Tangan Kanan-Tangan Kiri........III-9

3.6.11.2 Methods Tme Measurement

(MTM)................................................III-9

3.7 Analisa...............................................................................III-9

3.8 Kesimpulan dan Saran.......................................................III-9

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA

4.1 Pengumpulan Data............................................................IV-1

4.1.1 Pengenalan Produk..............................................IV-1

4.1.2 Pengenalan Kelompok........................................IV-6

4.1.3 Struktur Organisasi Shift 3..................................IV-8

4.1.4 Data Hasil Produksi............................................IV-9

4.1.5 Waktu Siklus Stasiun Shift 3...............................IV-18

4.1.6 Tabel Pengamatan Work Sampling.....................IV-24

4.1.7 Data Kecacatan...................................................IV-47

4.2 Pengolahan Data................................................................IV-50

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4.2.1 Bill of Material (BOM).......................................IV-50

4.2.2 Standard Operational Prosedure (SOP).............IV-52

4.2.3 Perhitungan Waktu Baku....................................IV-58

4.2.3.1 Uji Statistik.........................................IV-58

4.2.3.2 Waktu Siklus..........................................IV-154

4.2.3.3 Perhitungan Faktor Penyesuaian..................IV-171

4.2.3.4 Perhitungan Waktu Normal.........................IV-176

4.2.3.5 Perhitungan Faktor Kelonggaran.................IV-178

4.2.4 Perhitungan Work Sampling.....................................IV-185

4.2.4.1 Produktivitas................................................IV-185

4.2.4.2 Uji Kecukupan.............................................IV-188

4.2.4.3 Faktor Penyesuaian......................................IV-191

4.2.4.4 Faktor Kelonggaran.....................................IV-194

4.2.5 Peta Kerja...................................................................IV-212

4.2.5.1 Peta Proses Operasi......................................IV-212

4.2.5.2 Assembly Chart............................................IV-214

4.2.5.3 Peta Aliran Proses........................................IV-216

4.2.5.4 Diagram Alir................................................IV-221

4.2.5.5 Peta Tangan Kiri dan Tangan Kanan...........IV-222

4.2.6 Line Balancing............................................................IV-244

4.2.6.1 Parameter yang Berpengaruh........................IV-256

4.2.7 Quality Control..........................................................IV-261

4.2.8 Predetermined Time System.......................................IV-273

4.2.8.1 Peta Tangan Kanan dan Tangan Kiri...........IV-273

4.2.8.2 Methods Time Measurement (MTM)...........IV-292

BAB V ANALISA

5.1 Pengumpulan Data..............................................................V-1

5.2 Pengolahan Data..................................................................V-1

5.2.1 Bill Of Material (BOM)............................................V-2

5.2.2 Standard Operational Procedure (SOP)....................V-2

5.2.3 Analisa Uji Statistik...................................................V-2

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5.2.3.1 Perhitungan Uji Keseragaman Data.............V-2

5.2.3.2 Perhitungan Uji Kecukupan Data................V-3

5.2.4 Work Sampling dan Produktivitas..............................V-3

5.2.5 Waktu Normal............................................................V-5

5.2.5.1 Penyesuaian Pada Stasiun Pemotongan.......V-5

5.2.5.2 Penyesuaian Pada Stasiun Pelipatan............V-7

5.2.5.3 Penyesuaian Pada Stasiun Perakitan............V-7

5.2.5.4 Penyesuaian Pada Stasiun

Quality Control (QC)...................................V-8

5.2.6 Waktu Baku................................................................V-8

5.2.6.1 Kelonggaran Pada Stasiun Pemotongan......V-8

5.2.6.2 Kelonggaran Pada Stasiun Pelipatan...........V-9

5.2.6.3 Kelonggaran PadaStasiun Perakitan............V-10

5.2.7 Peta-peta Kerja...........................................................V-10

5.2.7.1 Peta Proses Operasi......................................V-10

5.2.7.2 Assembly Chart............................................V-11

5.2.7.3 Peta Aliran Proses........................................V-11

5.2.7.4 Diagram Aliran............................................V-11

5.2.7.5 Peta Tangan Kanan-Kanan Kiri..................V-12

5.2.8 Line Balancing dan Quality Control..........................V-12

5.2.8.1 Line Balancing.............................................V-12

5.2.8.2 Quality Control............................................V-15

5.2.9 Pengukuran Waktu Kerja Secara Tidak Langsung....V-17

BAB VI PENUTUP

6.1 Kesimpulan..........................................................................VI-1

6.2 Saran....................................................................................VI-1

DAFTAR PUSTAKA

LAMPIRAN

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