Electronic Theses and Dissertation

UMKM Bakery Banda Aceh merupakan usaha yang bergerak di bidang produksi roti dan masih menghadapi permasalahan produk cacat (defect) pada produk roti sosis. Penelitian ini bertujuan untuk mengetahui tingkat pengendalian kualitas, mengidentifikasi faktor-faktor penyebab defect, serta menyusun usulan perbaikan pada proses produksi roti sosis menggunakan metode Six Sigma dengan tahapan Define, Measure, Analyze, Improve, dan Control (DMAIC). Penelitian dilakukan menggunakan data produksi roti sosis periode Januari–Desember 2025. Hasil penelitian menunjukkan jumlah produk cacat sebanyak 2.185 unit dari total produksi 86.400 unit dengan defect rate sebesar 2,53%. Perhitungan Six Sigma menghasilkan nilai Defects Per Million Opportunities (DPMO) sebesar 8.430 dengan level sigma sebesar 3,89. Hasil tersebut menunjukkan bahwa proses produksi roti sosis telah berada pada tingkat yang cukup baik, namun belum memenuhi target maksimal defect sebesar 2% yang ditetapkan perusahaan. Berdasarkan analisis Pareto, defect yang paling dominan adalah roti gosong, diikuti roti tidak mengembang dan bentuk tidak seragam. Selanjutnya, analisis fishbone diagram menunjukkan bahwa penyebab defect berasal dari faktor man, machine, method, material, dan environment. Berdasarkan hasil analisis tersebut, usulan perbaikan yang diberikan meliputi peningkatan pengawasan pekerja, pemeriksaan dan perawatan oven secara berkala, standarisasi proses fermentasi, pengendalian kualitas bahan baku, kalibrasi timbangan, pelatihan pekerja, serta penyusunan Standar Operasional Prosedur (SOP) pada proses pemanggangan, fermentasi, dan pembentukan adonan. SOP yang disusun diharapkan dapat menjadi pedoman kerja dalam mengurangi jumlah defect dan meningkatkan kualitas produk roti sosis di UMKM Bakery Banda Aceh.

Kata Kunci: Six Sigma, Pengendalian Kualitas, Defect, Fishbone Diagram, DPMO.

UMKM Bakery Banda Aceh is a bakery engaged in bread production and still faces quality problems due to defective products in its sausage bread production. This study aims to determine the level of quality control, identify the factors causing defects, and propose improvement strategies for the sausage bread production process using the Six Sigma method with the Define, Measure, Analyze, Improve, and Control (DMAIC) approach. The study was conducted using sausage bread production data from January to December 2025. The results showed that there were 2,185 defective products out of a total production of 86,400 units, resulting in a defect rate of 2.53%. The Six Sigma calculation produced a Defects Per Million Opportunities (DPMO) value of 8,430 with a sigma level of 3.89. These results indicate that the sausage bread production process is performing at a reasonably good level; however, it has not yet achieved the company's maximum defect target of 2%. Based on the Pareto analysis, the dominant defects were burnt bread, followed by under-risen bread and irregular bread shape. Furthermore, the fishbone diagram analysis revealed that the causes of defects originated from the man, machine, method, material, and environment factors. Based on these findings, the proposed improvements include enhancing worker supervision, conducting regular oven inspection and maintenance, standardizing the fermentation process, improving raw material quality control, calibrating weighing scales, providing employee training, and developing Standard Operating Procedures (SOPs) for the baking, fermentation, and dough-shaping processes. The proposed SOPs are expected to serve as operational guidelines to reduce product defects and improve the quality of sausage bread produced by UMKM Bakery Banda Aceh. Keywords: Six Sigma, Quality Control, Defect, Fishbone Diagram, DPMO.