Institutional Repository UIN Sunan Kalijaga YogyakartaANALISIS LEAN SIX SIGMA UNTUK MEMINIMALKAN PRODUK REWORK PADA DEPARTEMEN ASSEMBLY LINE HOMECARE BED EXPORT ORIENTED PRODUCTS (STUDI KASUS: PT MEGA ANDALAN KALASAN)NIM.: 22106060046Muhammad Sigit DarmawanauthorPT Mega Andalan Kalasan (PT MAK) merupakan perusahaan manufaktur hospital equipment yang menghadapi permasalahan pada Assembly Line Export Oriented Products (EOP) berupa penurunan produktivitas lini produksi. Penelitian ini bertujuan menentukan nilai current state Process Cycle Efficiency (PCE) dan sigma level, mengidentifikasi jenis dan akar permasalahan waste, merancang usulan perbaikan, serta menentukan nilai future state PCE dan sigma level. Pendekatan yang digunakan adalah Lean Six Sigma dengan siklus DMAIC, menggunakan alat SIPOC Diagram, CTQ Diagram, Value Stream Mapping (VSM), Sigma Level Capability, Failure Mode and Effect Analysis (FMEA), Five Whys Analysis, dan Yamazumi Chart. Hasil penelitian menunjukkan nilai current state PCE sebesar 14,21% (kategori tidak efisien) dengan sigma level sebesar 3,01 dan DPMO 64.953 unit. Waste defect direpresentasikan oleh persentase produk Not Good (NG) rework sebesar 30,89%, dengan kasus respray sebagai penyumbang dominan (77,20% dari 1.123 kasus). Waste waiting ditemukan pada sub-departemen final assembly akibat cycle time sebesar 2.912,44 detik yang melampaui takt time. Hasil FMEA mengidentifikasi tujuh mode kegagalan kasus respray berdasarkan Risk Priority Number (RPN): karat (RPN 192), lecet (RPN 180), masir (RPN 140), varises (RPN 108), bercak oli (RPN 45), tipis (RPN 24), dan belang (RPN 24). Usulan perbaikan mencakup penyusunan SOP preventif, penambahan stasiun QC sebelum proses painting, ergonomic assessment pada workstation quality gate system painting, serta workload balancing pada sub-departemen final assembly. Apabila rekomendasi diimplementasikan, future state PCE diproyeksikan meningkat menjadi 51,09%, sigma level menjadi 3,69 dengan DPMO 14.377 unit, defective rate turun menjadi 7,36%, dan cycle time final assembly berkurang 201,48 detik menjadi 2.710,96 detik. Kata Kunci: Assembly Line EOP PT MAK, DMAIC, Lean Six Sigma, Process Cycle Efficiency (PCE), Sigma Level, Value Stream Mapping (VSM), Waste Defect, Waste Waiting, Workload Balancing, Yamazumi Chart.670 Teknik Industri2026-04-06UIN SUNAN KALIJAGA YOGYAKARTA;FAKULTAS SAINS DAN TEKNOLOGIThesis

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