Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Production Control Analysis of Main Body using

Statistical Process Control (SPC) Method
Ikrar Kurniawan Bahari , Fatihatul Azkiyah, Erry Rimawan
Faculty of Post Graduate Mercubuana University, Jakarta

Abstract:- This research will investigate PT. Astra Control (SPC) and we will describe the causes of the defect
Daihatsu Motor to producing Main Body. The production using Fish Bone Diagram.
process has quality standard which set company, this
research will analyze quality control Main Body II. LITERATURE REVIEW
production which is on production we still found defect so
that do not reach target quality. The research method use A. Quality
to processing the production defect data from Main Body Quality is the totality of features and characteristic of a
is Statistical Process Control (SPC) then the result will be product or service that bears on it’s ability to satisfy stated or
analyzed by Cause and Effect Analysis method. The result implied need (Heizer & Render, 2006: 253). Quality is not
of this research can be concluded that quality control in only seen in the product itself but also very complex involving
PT. Astra Daihatsu Motor requires improvement. Because all layers of the company as well as outside the company as a
of the graphic which is SPC method shown fluctuating and supplier or distributor and consumer. But basically the concept
irregular points that indicating the production process is of quality is often considered as conformity, the overall
deviate. characteristics or characteristics of a product expected by the
consumer(prasetyawaty, 2014).
I. INTRODUCTION
B. SPC
A company will develope product to provide value for In statistical process control is known as "seven tools"
its consumers in order to fulfill of their needs and desires (Metasari, 2008) ,. This Seven tools is a tool for quality
which the products have maximum condition of the quality. control and how to solve the problem. Seven tools are (Heizer
Therefore, the company must maintain the quality of its and Render, 2006: 263-268).
products in order to meet consumer expectations.
1. Check Sheet
Control and quality improvement in the company 2. Run Chart
especially manufacturing companies is needed to producing a 3. Histogram
products with has international standard so the product can 4. Control Chart
attract consumers in global competition. However, although 5. Pareto Diagram
the production process is done well and has high standard, in 6. Cause and effect Diagram
the field we could found many errors in the production process 7. Scatter Diagram
where at the time of the production process generate a
products that are not in accordance with the company quality Statistical Process Control (SPC) was discovered on the
standards . So the result of its product defect production. 1970s used to describe statistical techniques to monitor and
improve quality in the production process. Statistical Process
In this study, researchers will investigate departement Control is a process used to monitor standart, making
of Body Plant 1 part of division of PT. Astra Daihatsu Motor measurements and taking corrective action as a product or
(ADM). The department is tasked to assemble the frame for service is being produced (Heizer and Render, 2006: 268). In
Avanza and Xenia cars on the Main Body Line section. This production processes there are quality standards that have
production line has 3 lines, consists of Under Body, Side been set, therefore must always be in control and monitored to
Member, Roof. For Main Body production line already have maintain product quality.
quality standard set by company, so this research will analyze
quality control from Main Body production which in its In Statistical Process Control (SPC), there are 2 different
production still found disability so that does not reach target kind of data(Gaspersz,1998:43):
quality.
1. Attributes Data
From the background of the problem the company Attributes Data is a discrete qualitative data, Attributes
needs a quality control that is useful to suppress the Data is qualitative data that can be calculated for recording
occurrence of production defects so as to achieve the target and analysis. Meaning is the observed data for the quality
quality in accordance with the expected using quality control process can not be measured by value but can be observed in
methods which is statistical tools, the Statistical Process the characteristics

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Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
2. Variables Data
Variables Data is quantitative data that is measured by using a specific measurement tool for recording and analysis purposes.

C. Testing Data Adequacy

To ensure that the data collected is sufficiently objective. The Data Sufficiency Test uses the formula:

Where:
k = The confidence level
k = 95% = 2
s = Degree of thoroughness =5 %
N = Number of observation data
N’ = Number of theoretical data
If N’ ≤ N, so the data is considered sufficient, if N’ > N the data is considered not sufficient and it is necessary to add data.

III. RESEARCH METHODOLOGY

This research has a way of thinking how to analyze the level of production defects and identify the causes of these things can
occured as well as provide solutions to the company in order to control the quality of products that have been produced by PT. Astra
Daihatsu Motor. This research will generate recommendations for improving the quality of production in the future. Based on the
theoretical basis of the review, it can be arranged in framework study as follows.

Fig 1:- flow diagram of research

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Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
IV. DATA AND STATISTIC

A. Data Sample
This is report of the producing Main Body PT. Astra
Daihatsu Motor which are the data taken from Quality Control
Metal Finish Division.

Amount of Production Amount of Defect

Day Defect Proportion
(body) (body)

1 408 21 0,0515
2 426 3 0,0070
3 432 4 0,0093
4 484 13 0,0269
5 463 4 0,0086
6 488 11 0,0225
7 465 4 0,0086
8 477 8 0,0168
9 461 3 0,0065
10 450 12 0,0267
11 425 17 0,0400
12 492 35 0,0711
13 483 17 0,0352
14 459 21 0,0458
15 456 12 0,0263
16 417 14 0,0336
17 426 13 0,0305
18 424 8 0,0189
19 427 13 0,0304
20 424 12 0,0283
21 410 11 0,0268
22 444 23 0,0518
Table 1. Sample Data producing Main Body PT. Astra Daihatsu Motor

To ensure that the data collected is sufficiently objective.

Testing of data adequacy is done by referring to the concept of
statistics with the degree of accuracy and level of confidence.
Degree of thoroughness and level of confidence is to reflect
the level of certainty desired by researcher after deciding not
to make measurements in large numbers (population).

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Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Day Amount of Production (x) X2 From the table 2, we acquire result N’ =0.13 , so the data can
be considered sufficient because N’<N (N=22).

1 408 166464 B. Data Processing

2 426 The results of data processing which processed from
181476
table 1 by SPC method and the results are fully described the
3 432 186624 table below so as to make it easier to analyze the problem.
4 484 234256
5 463 214369
6 488 238144
7 465 216225
8 477 227529
9 461 212521
10 450 202500
11 425 180625
12 492 242064
13 483 233289
14 459 210681
15 456 207936
16 417 173889
17 426 181476
18 424 179776
19 427 182329
20 424 179776
21 410 168100
22 444 197136
9841 4417185
Table 2. Data Amount of Production

Day Amount of Production (body) Amount of Defect (body) Defect Proportion Deviation Standart UCL LCL

1 408 21 0,0515 0,008217 0,052651 0,003349

2 426 3 0,0070 0,007974 0,051921 0,004079
3 432 4 0,0093 0,007983 0,051948 0,004052
4 484 13 0,0269 0,007599 0,050798 0,005202
5 463 4 0,0086 0,007777 0,05133 0,00467
6 488 11 0,0225 0,007643 0,050928 0,005072
7 465 4 0,0086 0,007855 0,051564 0,004436
8 477 8 0,0168 0,007830 0,05149 0,00451
9 461 3 0,0065 0,008015 0,052046 0,003954
10 450 12 0,0267 0,008204 0,052611 0,003389
11 425 17 0,0400 0,008459 0,053378 0,002622
12 492 35 0,0711 0,007832 0,051496 0,004504

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Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
13 483 17 0,0352 0,007733 0,051198 0,004802
14 459 21 0,0458 0,007907 0,051722 0,004278
15 456 12 0,0263 0,007860 0,051581 0,004419
16 417 14 0,0336 0,008233 0,052698 0,003302
17 426 13 0,0305 0,008125 0,052375 0,003625
18 424 8 0,0189 0,008137 0,05241 0,00359
19 427 13 0,0304 0,008158 0,052474 0,003526
20 424 12 0,0283 0,008181 0,052542 0,003458
21 410 11 0,0268 0,008324 0,052972 0,003028
22 444 23 0,0518 0,008012 0,052036 0,003964
Table 3. results of data processing which processed from table 1 by SPC method

V. RESULT

Fig 2:- Result of Defect Proportion

Based on the image of the control chart above it can be influence it. The factors that affect and cause defects in
seen that the data obtained is not entirely within the Upper production as follows:
Control Limit (UCL) that has been calculated. In the research
days 12 and 23 are above the upper limit data that has been  Man, Operators who do the work involved in the
obtained so that it can be said that the process is not production process,do not check the welding gun
controlled. This indicates a deviation process. periodically so they do not know the components of the
tool worn out or not
Research on the field we found that the defect occurred  Machine, Occurrence of worn out on the cover welding
in the Front Door Opening section and therefore to reduce the gun because the absence of change
number of defects in production the next step is to investigate  Method, the absence of a reference welding process
the cause of the defect in production itself. By using Cause because each operator only uses estimates so that the
and Effect Analysis, so it will be known the relationship of welding process is not stable.
problems that arise with the causative factors and factors that

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Volume 3, Issue 6, June – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 Environment, Operator footwork is disrupted due to the [10]. Santora, Larisang . 2017. “Quality Control Analysis
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number of defects in the production process Front Door Method”. ROTOR Journal. Volume 7 Nomer 2.
Opening.

VI. CONCLUSION

From this research can be concluded that quality control

in PT. Astra Daihatsu Motor requires improvement. Due to a
high fluctuating and irregular point that indicates that the
production process is still deviated. The main cause of the
defect is the unstable welding process in which there is a
factor supporting the cause of the main problem is the absence
of periodic checks of welding gun periodically so operators
do not know the components of the tool are worn out and the
absence of a reference welding process because each operator
only uses estimates so that the welding process is not stable.
Corrective measurement can be done what if the cause of
production defects is overcome consistently.

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