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  • AN INSTALLATION OF A3 PROBLEM SOLVING

    METHODOLOGY TO DO CONTINUOUS

    IMPROVEMENTAT X TOOLS DEPARTMENT IN PT

    XYZ

    By

    Crissy Paramita Aisahana

    ID No. 004201200014

    An Internship Report submitted to the Faculty of Engineering

    President University in partial fulfillment of the requirements of

    Bachelor Degree in Engineering Major in Industrial Engineering

    2015

  • i | P a g e

    ACADEMIC ADVISOR

    RECOMMENDATION LETTER

    This internship report is prepared and submitted by Crissy Paramita

    Aisahana in partial fulfillment of the requirements for the degree of

    Bachelor Degree in the Faculty of Engineering has been reviewed and

    found to have satisfied the requirements for a report fit to be

    examined.

    Cikarang, Indonesia, June 30th, 2015

    Ineu Widaningsih, S.T., M.T.

  • ii | P a g e

    LETTER OF APPROVAL

    Hereby declare that internship report which written by Crissy Paramita

    Aisahana during period internship in Engineering Department, period March until

    June, all of the contents have been reviewed and it doesnt consist of PT. XYZ

    confidential matter.

    This internship report can be used as public document.

    Cikarang, June 30th, 2015

    Approved by, Acknowledge by,

    HR Representative Supervisor

    IP EF

    Senior Manager - Training & Development Supervisor

  • iii | P a g e

    INTERNSHIP REPORT IN PT XYZ,

    CIKARANG, INDONESIA

    By

    Crissy Paramita Aisahana

    ID No. 004201200014

    Approved by

    Ineu Widaningsih, S.T., M.T. Ir. Andira, M.T.

    Internship Advisor Internship Coordinator

    HerwanYusmira, B.Sc. MET, Mtech

    Program Head of Industrial Engineering

  • iv | P a g e

    ABSTRACT

    PT. XYZ is a toy manufacturing company located in Jababeka area, Cikarang, Bekasi,

    Indonesia. The problem happened in this company should always be solved immediately

    because the quality of tools and products are the most important things to be maintained by

    the company.Since X Tools Department in PT. XYZ is the tool making department that will

    make molds for toys production, the quality of the tools in X Tools Department should

    always be maintained. There are a lot of problems occur while making the tools for sure,

    because there are a lot of aspects to be seen as the causes such as man, material, method and

    machine. In order to decrease the time of solving the tools, the problem solving tools such as

    A3 problem solving methodology should be installed in the company. There are a lot of tools

    to support the contents in A3 form, the diagram, chart, sketch, or picture can be the best

    visual tools to be applied in A3 form. Installing the new system is not easy at all in the big

    multinational company. There are a lot of things to do such as make the timeline of making

    the A3, make the proper form of A3, make an A3 training material, make A3 flowchart and

    the people whose responsible of each tasks, train all the employees, do trial for the employees

    to make sure they understand about the training material which given to them, collect all the

    feedbacks from them, spread the questionnaire about the project, and at last the SOP of A3

    should be made. All the good preparation of installation is a must to do in order to make the

    problem lasts in the daily works.

    Keywords : Quality, Problem Solving, Quality Improvement, A3, Manufacturing.

  • v | P a g e

    ACKNOWLEDGEMENT

    This internship report is hardly to be done without God blessing, fabulous support, and

    motivation from others. Therefore, I would like to express my sincerely thank you and

    gratefulness to:

    1. Allah, the infinite sourcing. Thank You for Your bless and unconditional love towards

    me. My beginning, idea, and forever. Only You, my recline place.

    2. My beloved parents, Arifin Syukur and Helmi Fauziah. Thank you for bringing me

    into this world, for the continuous support, prayers, irreplaceable love to me and for

    allowing me the freedom of pursuing whatever dreams I have.

    3. My brother, Egbert Manggala Daniswara. Thank you for being the best brother

    anyone could have.

    4. Yehia Adel Youssef Elsoltany. Thank you for your never-ending support throughout

    the entire process, for the laughs, for your calmness and patience, and for our

    conversation about nothing and everything.

    5. Mrs. Ineu Widaningsih, S.T., M.T. as my internship advisor. Thank you for the

    guidance, advice, and everything that enrich my knowledge in completing this

    internship report.

    6. Mrs. Anastasia Lidya Maukar, ST., M.Sc., M.MT.and Ms. Ir. Andira, M.T. My

    academic advisor who always give guidance, direction, motivation, inspiration, and

    recommendation in doing and accomplishing this internship report. `

    7. Mr. Herwan Yusmira, BSc. MET., MTech. as Head of Industrial Engineering.

    8. Employee of PT. XYZ, who not only provides the company data but also give me

    motivation, direction, and suggestion in completing this internship report.

    9. My classmates in Industrial Engineering batch 2012 who always support, share the

    togetherness and joyful moments in this university life. Thank you for the time we

    spent together.

    10. My incredible best friends (Alfita, Yoana, Gandi, Rifi). Thank you for always be my

    side during good and bad days, and for being the best of friend anybody could have.

    11. Others that I cannot mention one by one but always give me motivation.

  • vi | P a g e

    TABLE OF CONTENT

    Contents ACADEMIC ADVISOR .............................................................................................................. i

    RECOMMENDATION LETTER ............................................................................................... i

    LETTER OF APPROVAL ......................................................................................................... 2

    ABSTRACT ................................................................................................................................ 4

    ACKNOWLEDGEMENT .......................................................................................................... 5

    TABLE OF CONTENT ............................................................................................................. vi

    LIST OF TABLES ...................................................................................................................... 8

    LIST OF FIGURES .................................................................................................................... 9

    LIST OF TERMINOLOGIES .................................................................................................. 10

    CHAPTER I INTRODUCTION ................................................................................................. 3

    1.1 Problem Background ................................................................................................... 3

    2.1 Problem Statement ....................................................................................................... 3

    3.1 Objectives .................................................................................................................... 3

    4.1 Scope ............................................................................................................................ 3

    5.1 Assumption .................................................................................................................. 3

    6.1 Research Outline .......................................................................................................... 4

    CHAPTER II LITERATURE STUDY ....................................................................................... 5

    2.1 Quality Improvement ................................................................................................... 5

    2.2 Quality Metrics ............................................................................................................ 6

    2.3 A3 Problem Solving Methodology ................................................................................ 6

    2.3.1 Contents ............................................................................................................... 8

    2.3.2 PDCA Cycle ........................................................................................................ 10

    2.3.3 7 Basic Quality Tools .................................................................................................. 11

    CHAPTER III RESEARCH METHODOLOGY ............................................................................ 15

    3.1 Initial Observation .............................................................................................................. 16

    3.2 Problem Finding .................................................................................................................. 16

    3.3 Literature Study .................................................................................................................. 16

    3.4 Data Collection .................................................................................................................... 17

    3.5 Data Analysis ....................................................................................................................... 17