QUALITY CONTROL ANALYSIS TO REDUCE THE NUMBER OF DEFECTS IN THE PACKAGING OF PG KREMBOONG SUGAR PRODUCTS USING SEVEN TOOLS METHOD

Quality control is an activity that must be carried out by a company so that the products produced are in accordance with the standards set by the company in order to meet customer satisfaction. This research was conducted in order to obtain the results of the quality control analysis which then the results of the analysis will be used as an effort to reduce the number of defects in product packaging in the future at PG Kremboong. This research in solving the problem using the seven tools method. This seven tools method uses 7 quality control tools, namely Check Sheet, Control Chart, Cause and Effect Diagram, Pareto Diagram, Histogram, Scatter Diagram and Stratification so that a quantitative measurement is produced that shows the extent to which management objectives have been achieved. From the analysis using the seven tools, the defects in granulated sugar with 50 kg packages were produced, namely, less light prints (146), torn packages (299), dirty packages (224) and loose seams (200). The defect with torn packaging is the most dominant type of defect. Improvement steps to reduce the number of defects in sugar packaging in the future are carried out on 5 factors, namely humans, methods, machines, materials and the environment based on a comparison between the causes of the problem and the standards applicable in the company.


INTRODUCTION
Quality is a characteristic of a product in its ability to meet predetermined needs and is latent (Heizer et al, 2015). Meanwhile, Fuad et al (2006), quality is the advantage that the product has. Quality in the view of consumers is something that has its own scope that is different from the quality in the view of the manufacturer when issuing a product that is commonly knownfor its true quality. Quality control is a management tool to ensure quality, because basically no two products produced by a production process are the same, it cannot be avoided that there are variations. Experimental designs can be used in conjunction with statistical process control to minimize process variability and produce production that is ultimately defect free (Yetti, 2016). Statistical testing is needed to solve problems like this, in quality control these statistical techniques are applied to check and test data to determine standards and check the suitability of products to achieve maximum manufacturing operations, and usually result in lower quality costs and increase the level of competitive position.
Kremboong Sugar Factory is one of the sugar companies under the supervision of PT Perkebunan Nusantara X which is located in Krembung Village, Krembung District, Sidoarjo Regency, East Java. This study identifies the types of defects and factors that cause defects in granulated sugar product packaging which will then be used as a basis for taking corrective steps to reduce the number of defects in sugar packaging in the future.
This research in solving the problem using the seven tools method. The problems discussed were the identification of the number of defects in sugar packaging and the proposed improvements in an effort to reduce the number of defects in sugar packaging at the PG Kremboong Sugar Bagging (Warehouse) department. The data taken in this study are the daily sugar production output and defect data in granulated sugar packaging. The collection of data on the number of production and defects in granulated sugar products is carried out daily, which in one day (24 hours) there are 3 work shifts. Data on defects in products is obtained based on reports from operators for each work shift which are then added up and checked for correctness to the relevant supervisor. This research in solving the problem using the seven tools method. The problems discussed were the identification of the number of defects in sugar packaging and the proposed improvements in an effort to reduce the number of defects in sugar packaging at the PG Kremboong Sugar Bagging (Warehouse) department. The data taken in this study are the daily sugar production output and defect data in granulated sugar packaging. The collection of data on the number of production and defects in granulated sugar products is carried out daily, which in one day (24 hours) there are 3 work shifts. Data on defects in products is obtained based on reports from operators for each work shift which are then added up and checked for correctness to the relevant supervisor.
2. Research Methods Basically, seven tools are used to solve problems that occur in the production process. Seven tools are 7 tools used to support quality control. as mentioned also by Heizer and Render in his book Operations Management (2006: 263-268), including: (a) Check Sheet A check sheet is a simple designed sheet containing a list of things needed for data recording purposes so that users can collect data easily, systematically, and regularly when the data appears at the location of the incident.
(b) Scatter Diagram A scatter diagram is a graph showing a pair of numerical data in a Cartesian coordinate system, with one variable on each axis, to see the relationship between the two variables. If the two variables are correlated, the coordinate points will fall along the line or curve.
(c) Fishbone Diagram Fishbone diagrams (fishbone diagrams) are often called Ishikawa diagrams or cause and effect diagrams (cause-and-effect diagrams). Fishbone diagram is a tool for identifying various potential causes of an effect or problem, and analyzing the problem through a brainstorming session.

(d) Pareto Chart
Pareto chart (pareto chart) is a chart that contains a bar graph and line graph, a bar chart shows the classification and value of data, while a line chart represents the cumulative total data. The pareto chart principle is in accordance with Pareto law which states that a group always has the smallest percentage (20%) of value or has the greatest impact (80%).
(e) Flow charts Flow charts are a tool for visualizing the process of completing a task in a step-by-step manner for the purposes of analysis, discussion, communication, and can help us find areas of improvement in the process (Tjiptono, Fandy & Anastasia Diana, 2003)

(f) Histogram
A histogram is a bar graph-like tool used to show the distribution of frequencies. A frequency distribution shows how often each different value in a data set occurs. The data in the histogram is divided into classes, the observed value of each class is shown on the X axis.
(g) Control Chart Control chart or control chart is a map that is used to study how the process changes over time. The data are plotted in chronological order. The control chart always consists of three horizontal lines, namely: Center line, a line that shows the mean or average value of the quality characteristics plotted on the control chart. Upper control limit (UCL), a line above the center line that shows the upper control limit. Lower control limit (LCL), a line under the center line that shows the lower control limit     d. Scatter Diagram Scatter diagrams are used to determine the correlation between two variables, namely cause and effect, so that the points with the largest percentage of defects can be found. The following are the results of data processing using a scatter diagram:

CONCLUSION
The following are the conclusions that have beenmade regarding defects that occur in granulated sugar products with a 50 kg package, as follows: (1) Types of defects in granulated sugar with 50 Kg packs that occurred at PG Kremboong in the period July -September 2018 using Seven Tools were light printing (146), torn packaging (299), dirty packaging (224) and loose seams (200).
(2) Defects with torn packaging are the most dominant type of defect, using a fishbone diagram, it is known that there are several factors that cause defects with torn packaging in granulated sugar products, namely human factors, methods, machines, materials and environment.