IMPLEMENTASI NEW SEVEN TOOLS DAN FAILURE MODE AND EFFECT ANALYSIS BERBASIS SIX SIGMA GUNA PENINGKATAN KUALITAS DEMINERALIZED WATER : (Studi Kasus: Unit Demin III A - PT Petrokimia Gresik)

ali albana; Said Salim Dahda

Authors

ali albana universitas muhammadiyah gresik
Said Salim Dahda Universitas Muhammadiyah Gresik

Keywords:

New Seven Tools, Failure Mode and Effect Analysis (FMEA), Six Sigma, Peta Kontrol, Demineralized water

Abstract

PT Petrokimia Gresik memerlukan pasokan demineralized water berkualitas tinggi untuk mendukung kinerja turbin dan boiler dalam proses produksi. Kualitas demineralized water berperan penting terhadap efisiensi energi dan keberlangsungan operasional. Penelitian ini bertujuan menganalisis jenis, penyebab, serta pengendalian kecacatan air demin melalui integrasi metode Six Sigma, New Seven Tools, dan Failure Mode and Effect Analysis (FMEA). Hasil menunjukkan bahwa kecacatan tertinggi terjadi pada parameter Total Hardness (TH), SiO₂, dan Conductivity. Penyebab utama mencakup proses regenerasi resin yang tidak optimal, ketidakstabilan parameter operasional, serta lemahnya pengendalian mutu dan kalibrasi alat. Nilai DPMO sebesar 20.673,48 dan level sigma 3,5 mengindikasikan bahwa proses belum mencapai kualitas optimal, meskipun masih dalam batas kendali statistik. Usulan perbaikan meliputi optimalisasi SOP regenerasi resin, pelatihan operator, penjadwalan kalibrasi dan inspeksi alat, pengembangan sistem monitoring online, serta preventive maintenance rutin pada unit kation, anion, dan filter. Pendekatan ini diharapkan mampu meningkatkan kualitas demineralized water secara berkelanjutan.

PT Petrokimia Gresik requires a high-quality supply of demineralized water to support the performance of turbines and boilers in the production process. The quality of demineralized water plays a crucial role in energy efficiency and operational continuity. This study aims to analyze the types, causes, and control of defects in demineralized water through the integration of the Six Sigma method, New Seven Tools, and Failure Mode and Effect Analysis (FMEA). The results indicate that the highest defect rates occur in the parameters of Total Hardness (TH), SiO₂, and conductivity. The main causes include suboptimal resin regeneration processes, instability in operational parameters, and weak quality control and instrument calibration. A DPMO value of 20,673.48 and a sigma level of 3.5 indicate that the process has not yet reached optimal quality, although it remains within statistical control limits. Proposed improvements include optimizing SOPs for resin regeneration, operator retraining, scheduling regular calibration and equipment inspections, developing an online quality monitoring system, and implementing routine preventive maintenance on key units such as cation, anion, and filters. This approach is expected to sustainably enhance the quality of demineralized water.

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