Analisis Hambatan Operasional Dan Potensi Implementasi Siklus PDCA Dalam Pengendalian Kegagalan Proses Di Rim Line PT Autokorindo Pratama

Achmad Javier Rajendra; Suaibatul Aslamiyah

doi:10.37888/bjrm.v9i2.1110

Authors

Achmad Javier Rajendra Universitas Muhammadiyah Gresik
Suaibatul Aslamiyah Universitas Muhammadiyah Gresik

DOI:

https://doi.org/10.37888/bjrm.v9i2.1110

Keywords:

Process Failure, Plan–Do–Check–Act (PDCA), Quality Control, Operations Management, Steel Wheel Manufacturing

Abstract

This study aims to analyze the conditions and patterns of product repair processes and examine the potential implementation of the Plan–Do–Check–Act (PDCA) method as a continuous improvement approach in reducing repair frequency at the Rim Line of PT Autokorindo Pratama. This research employs a qualitative approach with a case study design. Data were collected through non-participant observation, semi-structured interviews with key informants across structural positions, and operational document analysis of daily steel wheel production quality reports. Data analysis follows an interactive qualitative model involving data reduction, data display, and conclusion drawing. The results indicate that high repair rates are driven by 5M factors, including human factors (operator precision and manual setting subjectivity), work methods (lack of standardized cleaning procedures), and equipment (wear of clamping moulds and tool sharpness). Implementing the PDCA framework demonstrates significant potential in stabilizing operational quality by enhancing preventive planning, daily shift controls, early problem detection, and standardized work procedures. Sistematic PDCA implementation enables the company to suppress accumulated repair products, improve internal control accuracy, and sustainably optimize operational cost efficiency.

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