Volume 4, Number 3, March 2023 e-ISSN: 2797-6068 and p-ISSN: 2777-0915
Tuti Wiyanti, Fitrina
Lestari, Yoedani, Yusuf Iskandar
Universitas Nusa Putra, Indonesia
Email: [email protected],
[email protected], [email protected], [email protected]
|
KEYWORDS Quality control; quality
standards; achievement of quality standards |
ABSTRACT The objectives of this study were achieved through the
use of qualitative descriptive analysis, quantitative statistical ana-lysis,
and quality control. To meet the quality target set by the Buyer, which is
below 1.9%, it is necessary to know how many types of defects are found in
the Finishing section and in the Final Inspection and how to reduce defects
through the use of control strategies and methods applied by PT. Single
Estuary. The data for this study comes from the statistics of production and
damage to the Finishing department between May and August. Based on the
findings of the study, it can be said that the implementation of quality
control in this enterprise has been carried out quite successfully, with a
noticeable improvement and a good quality improvement and is worthy of
appreciation. These results show the seriousness or level of commitment of
the management of PT. Muara Tunggal to continuously improve the quality
according to the requests of buyers or buyers. The reduction in defects was
first seen in early September 2022 with a defect rate of around 1.4%. Regarding
the recommendations that can be made based on the findings, these include
selecting raw materials according to Buyer's standards, hiring skilled labor,
maintaining strict work ethics, providing training to employees to improve
their skills, maintaining machines regularly, and improving neatness,
comfort, and a safe workplace. |
INTRODUCTION
Manufacturers must be able to produce high-quality goods in order to
compete in an increasingly cruel world of globalization and rapid scientific
and technological advances (Suryono, 2019). One of the most important aspects of a production process, whether the
product is intended for domestic consumption or export, is product quality (Sherly et al., 2021). Since all goods manufactured by the company for the American market must
meet the quality standards, or AQL 2.5 quality, which are strict and are the
standards that have been established for garment products to be marketed in
America, the quality issue of clothing products is very important. Today's
companies need to have a competitive advantage to compete in this cruel market.
Only a business that can provide a high-quality product or service in
accordance with the wishes of the consumer will succeed in the market (Rossanty et al., 2018).
Competition is more about product quality than about the level of
productivity of the company or the price of products (Ariani, 2011). High-quality products at competitive costs are just one of the
requirements to dominate the market, and both can be achieved by increasing
productivity, efficiency, and quality. A high-quality product must, on the one
hand, meet the requirements set by the buyer, but on the other hand, it must
satisfy the user or customer (Musfar & Se, 2020). Customer satisfaction is a concern for product quality because during
manufacturing, the product is in accordance with what the customer (buyer)
wants or expects, making product quality a crucial factor that significantly
affects customer satisfaction. performance of other business fields (Rangkuti, 2013). Product quality improves along with a decrease in the failure rate or
rejection of the product.
Quality is one of the key determinants of a company's
ability to survive in the face of intense industry competition. Defined as the
totality of product attributes that support its ability to meet specific or defined
needs, while quality control is an effort to organize the production process to
run smoothly in accordance with established quality standards to maintain the
company's capabilities. to produce high-quality products (Tirtayasa et al., 2021). According to Crosby
(1979), quality is conformity with requirements, meaning that according to what
is required or standardized, a product is said to be of high quality if it
meets established standards. Quality standards include raw materials,
production processes, and finished products. Handoko (1999) defines quality as
a factor contained in a product that causes the product to be of value
according to the purpose for which the product is produced. On the contrary, a
product is said to be of high quality if it can fully satisfy the customer,
that is, if it meets what the customer expects from a product, according to
Feigen-baum (1986), who also claims that quality is full customer satisfaction.
The purpose of quality control is to continuously avoid the production of
goods that do not meet the intended quality standards (second quality) and be
able to select, organize and evaluate quality so that customers are happy and
the business does not suffer (Chandra & Ratnamurni, 2022). The entrepreneur's goal in managing QC is to generate profits in a
flexible way while ensuring customer satisfaction, return on investment, and
long-term business profitability. If there are unique problems during QC
testing and inspection, studies need to be carried out so that they can be used
to address problems in the production area.
As a result, the company uses the following procedures for the main stages
of the quality control process, namely:
1.
Cost Control
Cost control with the aim of producing goods at affordable prices
2.
Production Control
Production control seeks to accelerate, streamline, and
ensure the quantity produced in accordance with the target achievement strategy
3.
Standard Control Product
Specifications
This supervision includes product appearance, comfort, and physical
characteristics
4.
Delivery Control
The arrangement to keep items on a delivery schedule has
an impact on how quickly the item is delivered.
There are three kinds of control times based on the length of time it takes
to carry out quality control of garment products:
1.
Preventive control
That is the checking that is carried out before the
production process begins. Its purpose is to ensure that production goes
according to plan and to avoid the creation of substandard goods or defects.
2.
Monitoring Control
That is the type of control used in the manufacturing
process. Its purpose is to keep an eye on the actions involved and, if there
are any irregularities, immediately correct them and track them.
3.
Repressive Control
4.
Control and
supervision activities are carried out after the completion of all production
processes.
PT. Muara Tunggal is a clothing business engaged in CMPH (Cutting, Making,
Packing, and Handling). Although most of the company's sales come from America,
the company accepts orders from vendors for outside markets. Businesses
implement systems to check product quality so that they meet the requirements
for products sold in America. In the current era of globalization, free trade
has forced manufacturers to engage in competition to increase the quantity and
quality of goods and services produced or provided in response to the demands
and tendencies of the global market. The company is dedicated to producing high-quality
goods for export and anticipates that as a result of the quality received by
customers, cooperation will be developed in the production of high-value and
good-quality apparel.
Conducting quality control over manufacturing process activities carried
out is important to ensure consistency in the quality of the products produced
and in accordance with market needs (Novansyah & Harahap, 2022). Quality control is very important because it can decide whether a
business is successful or unsuccessful in achieving its goals (Yuliana et al., 2022). Product control is an attempt to determine the minimum damage limit,
identify the root cause of the damage, and determine what steps must be taken
first to reduce the damage in order to occur quickly and handled properly (Saputra & Mahbubah, 2021). Many damaged or damaged goods can be produced as a result of constantly
inefficient control activities, and production goals in terms of quantity and
quality may not be met. Every manufacturing activity requires quality control
because the quality of a product or service is a reflection or benchmark of how
successfully the business carries out its production activities. A planned
process called quality control is used to achieve, maintain, and improve the
quality of a product or service so that it meets the requirements and can
satisfy customers (Oakland, 2012).
The reality on the ground shows that a successful and survivable business
must have a quality program because a quality program will be able to eliminate
waste and increase business competitiveness, leading the business to view
quality as an important element. which brings success. Therefore, quality
control is a guarantee of the company's products, aiming to ensure that the
products produced meet the requirements or quality standards that have been set
by the buyer and the company (Akbar, 2018). However, the company's strategy can vary, all based on company policies
or also adjusted to the company's vision and mission, as well as company goals
and environmental factors that can affectthe company.
The objectives of quality control of garment products are:
1.
Obtain assurance that
the quality of the goods or services produced meets the quality criteria set by
the buyer at the most reasonable or cost-effective price.
2.
Provide instructions
to each employee in charge of the garment quality control department and to
each employee directly involved in the production process.
3.
Realizing
high-quality clothing products that meet the needs of users or buyers.
The business will conduct inspections or inspections to
guarantee the high quality of the goods or products. An important component of
quality control is inspection, which includes finding out whether the input or
output meets the quality requirements of the brand (Winarko, 2018). Stopping the production of defective parts or useless services is the
purpose of inspection activities. When inspecting a garment order, an inspector
must follow the flow chart or process flow of the quality inspection system
according to established or regulated criteria, regardless of whether the order
is ready to ship or not and regardless of its quality. Additional name: AQL
(Acceptable Quality Level). Moreover, the objectives of this study were
achieved through the use of qualitative descriptive analysis, quantitative
statistical analysis, and quality control.
RESEARCH METHOD
This research method is qualitative descriptive analysis,
quantitative statistical analysis. It was carried out at PT. Muara Tunggal Jl.
Perintis Ke-merdekaan No.126 Kp. Kebon Randu RT.03/22 Kel.Cibadak Kec.Cibadak
Kab.Sukabumi West Java Indonesia. The case study approach is used in this
research method, which is to take a problem, evaluate it by quality control
using a chart or chart, specifically to control the number of errors per unit
of output, and then apply it to the case.
This observation
is carried out by making a number of direct observations on the object of
study, then documenting any information or events that are directly related to
the production process and become the basis for subsequent writing.
Direct observation is the method the author uses to collect data. The
author makes direct observations by collecting company data and conducting
direct interviews with company owners, section heads, or department heads.
Based on information collected from PT. Muara Tunggal during the time span of
May 2022 to August 2022 for clothing products. Whether the finished garment item
meets the quality requirements set by the buyer or business, quality control is
implemented. Clothes are advertised as good quality, but only if there are no
signs of damage such as broken seams, discarding dirty, torn, or dirty threads,
etc. The author will do so by using statistical quality control analysis, a
problem-solving strategy that utilizes statistical techniques to monitor,
organize, analyze, manage, and improve products and production processes. In
the Finishing stage and during the Final Inspection at PT. Single Estuary, will
be proven by a Pareto diagram to determine the type of damage and a Fishbone
Diagram to determine the cause of clothing damage.
The author uses qualitative descriptive techniques, which seek to explain
theory or practice in the field or describe the nature of a situation, to
provide a descriptive, methodical, and accurate picture of quality control
procedures and their use in PT. Single Estuary. According to theory and
research in PT. Muara Tunggal, the company performs quality control by direct
inspection using statistical quality control, or SPC (Statistical Processing
Control). When goods or services are produced, standards are monitored,
measurements are taken, and corrective actions are performed using the SCP
process can be exported, allowing the production and quality control
departments to carry out effective production prevention and control before the
goods are delivered to the buyer (Fournier et al., 2021).
The use of statistical quality control PT. Muara Tunggal uses quality
control tools from SPC, which has seven (seven) main statistical tools that can
be used as such tools:
Data Analysis (Check sheet)
The first step in statistical quality control analysis is to create a table
of the number of products and products that are damaged or damaged, and the
creation of this table will facilitate the process of collecting data and
analyzing.
Histogram
A histogram is a graphical representation of the distribution of data or
the frequency of different values that occur in a data set. Its purpose is to
inform management and support decision-making in an effort to continuously
improve operations.
Figure 2. Defect
percentage Finishing
period May – August
In the Histogram table, it can be seen that the types of defects in the
finished wear that most often occur are Broken stitch or broken stitch, Remove
the thread is not clean or still long, and Skip stitch or jump stitch.
Control Map
(P-chart)
After making a histogram, the next step is to create a control map chart
(p-chart) which is used to find out whether quality control is carried out in
PT. The first step in creating a control map of whether a Single Estuary is
under control or not is:
Calculating the percentage of disability
Create a center line or line that shows the middle or average value
The line above the center line that displays the upper control boundary is
known as the UCL (Upper Control Limit).
The lower control limit, or LCL, is the line that appears below the center
line and displays the lower control boundary.
We can determine whether the process variation is consistent (within the
control limit) or outside the control boundary by using the control chart.
Below is the formula in the P chart:
p =
p̅ =
CL = p̅
UCL = p ̅ + 3 √p ̅ (1 − p̅)
LCL = p ̅ − 3 √p ̅ (1 − p̅)
Information:
p: the percentage of inaccuracy of each sample
X: The proportion of damaged items in each sample.
n: how many samples were collected during the inspection.
p̅: Error proportion control map centerline
Table 1. P Chart control map
|
Damage types |
Total |
Median |
UCL |
LCL |
Average |
17751 |
|
Broken Stitched |
32570 |
17751 |
45793,79 |
-10291,54 |
Std deviation |
9347,55 |
|
Uncut thread end |
30233 |
17751 |
45793,79 |
-10291,54 |
Average range |
|
|
Skip Stitch |
21775 |
17751 |
45793,79 |
-10291,54 |
|
|
|
Open Seams |
14101 |
17751 |
45793,79 |
-10291,54 |
|
|
|
Poor Shape |
13671 |
17751 |
45793,79 |
-10291,54 |
|
|
|
Dirty/ oil |
11158 |
17751 |
45793,79 |
-10291,54 |
|
|
|
Puckering |
10233 |
17751 |
45793,79 |
-10291,54 |
|
|
|
Uncut thread end |
30233 |
17751 |
45793,79 |
-10291,54 |
|
|
Diagram Pareto
Pareto diagrams are
one of the tools that are often used in quality control. Basically, a Pareto
chart is a bar chart that displays problems in order of number of events; The
sequence starts from the most to the least. In its application, the Pareto diagram
is very helpful in determining and identifying the priority of the problem to
be solved; The most frequent problems are the top priority for action.
Table 2. Data on damage type
results in QC Finishing Period May - August
|
Damage Type |
Total |
Total Cumulative |
Percentage |
Percetage Cumulative |
|
Broken
Stitched |
32570 |
32570 |
23% |
23% |
|
Uncut thread
end |
30233 |
62803 |
21% |
44% |
|
Skip Stitch |
21775 |
84578 |
15% |
60% |
|
Open Seams |
14101 |
98679 |
10% |
69% |
|
Poor Shape |
13671 |
112350 |
10% |
79% |
|
Dirty/ oil |
11185 |
12353 |
8% |
87% |
|
Puckering |
10233 |
133768 |
7% |
94% |
|
Pleated |
8241 |
142009 |
6% |
100% |
Figure 4. Pareto
Diagram Data on damage type results in QC Finishing
Pareto diagram analysis from the
data mentioned above shows that the Finishing part suffered the most damage to
the garment production process from May 2022 to August 2022., for the highest
level of damage, namely clothing damage from Broken stitch or broken stitches
which was 32,570 pcs or 23%, for the second level of damage, namely Uncut
thread end or discard unclean thread, which was 30,233 pcs or 21%, this is likely due to the lack of care for
sewing operators when after the completion of the sewing process, they do not
dispose of the thread cleanly in accordance with the SOP.
For the third damage, namely skip stitch of 21,775 pcs or 15% caused by
poor machine quality, dull needles, and lack of prevention carried out during
the production process, for example, routinely changing needles regularly.
Fish Bone Chart
The shape of the tool was similar to that of a fish bone,
with the fish head representing the root cause and each bone standing as a
potential source of error. The way to start a causal diagram is to use four
categories of materials, machinery or equipment, people, and methods. 4M serves
as a good checklist for initial analysis, and as the chain progresses, each
cause is connected in separate bones along the chain.
Below is an example of a causal diagram created by QA PT. Estuary Stay.
Figure 5.
FishBone Analysis Broken Stitch
In making a causal diagram this time, it is to take from
the data the most defects or damage found during checking in the QC Finishing
section and during the Final Inspection (Broken Stitch).
To solve this
problem, the company must carry out regular and thorough maintenance of the
machines used in the production process. This maintenance should be performed
by a staff member experienced with the machine, ensuring that serious engine
malfunctions are dealt with quickly, precisely, and correctly. In addition,
businesses should have or provide a good spare machine so that it can be used
as a replacement in the event of engine failure.
Concentration and experience are important components to help the
production process succeed for the human or labor category. Employee discipline
also results in employees being lazy, so that work is not carried out properly,
lack of experience in the production process, and lack of understanding of
clothing design. Employees are tired and lack concentration due to the large
number of orders or production targets so that employees have to work quickly,
sometimes even have to work overtime, and this causes the ongoing production
process to suffer a lot of damage or defects. Companies should select
candidates with experience in their respective fields when hiring new employees
to solve this problem. In addition, to deal with workers who lack discipline,
the company must offer bonuses for hard work, punctuality, perseverance, and
compliance with goals. That way, workers will be encouraged to maintain
discipline and put aside their laziness.
For the category of methods, the quality control method in the company's
production process is quite good, but the implementation is less strict due to
the lack of supervision from the supervisor, which results in still errors, and
also the lack of training for which many operators still lack knowledge about
how to sew properly.
To address this issue, businesses should continue to monitor the use of
quality control procedures on operator expertise by conducting regular training
sessions.
Research Project Management
Project management activities This research is carried out by involving
each Division or each Department, and here it is explained what are the
elements of the planning process of this research project and also project
control, namely by ensuring that all activities have been identified and
ensuring that tasks are completed in the correct order.
The Initation stage or starting, namely the Commitment of PT. Muara Tunggal
to improve Quality and achieve the IQP standard of 1.9%, in this stage the
Management collects data and makes the data a tool to carry out improvement
projects regarding quality.
Table 3. Number of defects for the
period May – August
|
No |
Damage Types |
Total |
Production Output |
Percentage |
|
1 |
Broken Stitched |
32570 |
7666742 |
0.42% |
|
2 |
Uncut thread end |
30233 |
7666742 |
0.39% |
|
3 |
Skip Stitch |
21775 |
7666742 |
0.28% |
|
4 |
Open Seams |
14101 |
7666742 |
0.18% |
|
5 |
Poor Shape |
13671 |
7666742 |
0.18% |
|
6 |
Dirty/ oil |
11185 |
7666742 |
0.15% |
|
7 |
Puckering |
10233 |
7666742 |
0.13% |
|
8 |
Pleated |
8241 |
7666742 |
0.11% |
The Planning stage is PT. Muara Tunggal conducts Brain Storming to carry
out plans or corrective actions that will be taken to be able to make
improvements immediately.
Figure 7.
Schedule Training Sewing
Furthermore, management carries out execution or implementation in the
field to carry out or carry out the plans that have been prepared, namely by
conducting training to all Qc staff and sewing staff as well as training for
operators both sewing and QC using video or training directly.
Figure 8. Training QC and Sewing
Monitoring or supervising after training, whether the results of the
training are carried out or not in daily work activities, monitoring is also carried
out with an assessment or assessment from each section
head to measure the extent of the improvement shown by employees after the
training.
Figure 9. Research Experience
In order to increase the publication of scientific articles at the
international level, the author really needs knowledge about increasing the
knowledge of writing articles to the international level, how articles can be
interesting so that International journals can publish them, therefore the
author wants to share research experiences in writing international
proceedings.
Here are the stages of the author writing International proceedings:
Stages of Scientific Article Creation
Determining the Subject, topic, theme, and focus of writing, Searching for referral sources is directed to access
reputable repositories, citations are required using the references
application.
Supervisor Revision Stage
After finishing making a scientific article, the author revises with the
supervisor, where the plagiarism check is carried out later towards the end,
after the plagiarism check, the stage is paraphrase to minimize similitary,
proofreading is also carried out by the supervisor as the final examination
regarding the typo.
Refinement Stage
At this stage, the author makes improvements to the writing of scientific
articles when they have been revised with the supervisor, and also prepares
scientific articles for the next stage.
Submit Stage
At this stage, the author starts from hunting what journals will be
targeted for publication of the author's articles, the author knows what
journals are suitable for the author's articles, then of course the author will
target journals that are indeed focused on the field that the author is
researching. How to submit articles through the system that has been provided.
The author must first register to send, after which they will receive a page
for their own personal profile. All submission procedures, including writing
titles, abstracts, and keywords, as well as uploading article content, are
carried out on the profile page.
Machinery, For the category of machinery, the machine is the main equipment
and an important component in the production process. When there are
significant problems with the machine or non-conformity in the machine, the
production process should be temporarily stopped for repair, and if the engine
malfunction is severe, it should be stopped for quite a long time.
Alternatively, we can replace the engine with a new one from the same engine
backup to avoid delays.
Man, labor, Concentration and experience are important components that help the
manufacturing process for the category of human or labor. Employee discipline
also results in employees being lazy, so that work is not carried out properly;
lack of experience in the production process; and a lack of understanding of
clothing design; All of which causes the ongoing production process to suffer a
lot of damage or defects. Employees are tired and lack concentration due to the
large number of orders or production targets so that employees have to work
fast and sometimes even overtime; also causes the ongoing production process to
be damaged or defective. Companies can select candidates with experience in
their respective sectors when hiring new employees to address these issues, and
to address workers who lack discipline, they should reward employees for doing
a good job, arriving on time, working attentively, and achieving their goals.
Employees are encouraged to maintain discipline and put aside their laziness.
The quality control method, for the category of methods, the quality
control method used by the company in the production process is quite good, but
the implementation is less strict due to the lack of control from the
supervisor so there are still some errors and also because of the lack of
training to the operator so that many operators still do not understand how to
sew properly. To address this issue, businesses should continue to monitor the
use of quality control procedures on operator expertise by conducting regular
training sessions.
After the improvement of the existing work system in production during May
to August 2022, the results of reducing defects or production defects can be
seen from the Factory Performance below:
Figure
10. Factory Peformance Update
The decrease in defects or production defects began to be seen in early
September 2022 with a defect rate of around 1.4% and these results showed the
seriousness or form of commitment from the Management of PT. Muara Tunggal to
always improve Quality in accordance with buyer requests.
CONCLUSION
This can be inferred from the background of the research, data from the
research as a whole, and the research that has been carried out:
There are several types of defects found in finishing and during final
inspection including Broken stitch, discard unclean threads, skip stitch,
stains, puckering etc., and these defects are found because they are less
concerned about some employees about product quality and are also caused by the
incomprehension of employees how important it is to maintain quality for a
product.
TheQuality
Management system that is applied holds such an important responsibility in the
continuity of the company's operational activities, including by communicating
between each division intenselybecause effective communication is very
important for all quality control efforts, and also training for all staff and
operators to better understand and master their respective job desc, and after
training will be carried out, an evaluation of the results of training will be
carried out for See how much impact
training has on the smooth running of the production process and quality
control
Positive and
significant quality improvement The decrease in
production defects or de-fects began to be seen in early September 2022 with a
defect rate of around 1.4% and these results show the seriousness or form of
commitment from the Management of PT. Muara Tunggal to always improve the
Quality as requested by buyers.
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Copyright Holders:
Tuti Wiyanti,
Fitrina Lestari, Yoedani, Yusuf Iskandar (2023)
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Devotion - Journal
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