Upaya Pengendalian Kualitas Guna Menurunkan Angka Cacat Reclaiming pada Industri BOPP PT XYZ Tbk Menggunakan Metode Root Cause Analysis (RCA)

Abstract

PT XYZ Tbk is a Biaxially Oriented Polypropylene (BOPP) film manufacturing company that continues to face a high level of reclaiming activities due to product defects. This condition leads to increased raw material waste, higher production costs, and reduced production efficiency. This study aims to identify the root causes of reclaiming defects and develop improvement recommendations to reduce the defect rate using the Root Cause Analysis (RCA) method with the fishbone diagram and 5 Whys approach. This research employed a qualitative method using reclaiming data collected from July to September 2025 through observations, interviews, and company documentation. The results showed that the total reclaiming waste reached 1,079,223.88 kg, with the largest defect category consisting of Cut Sheet, Edge Trim, and Reject Roll, accounting for 49.97%, followed by Jumbo Balance at 32.16%. The RCA results indicated that the root causes of the defects were influenced by man, machine, method, material, and environment factors, which are interconnected throughout the production process. Based on these findings, the proposed improvements include enhancing operator competence through training, implementing regular preventive maintenance, strengthening compliance with Standard Operating Procedures (SOP), improving material quality control, and optimizing workplace conditions. The implementation of these improvement strategies is expected to reduce reclaiming defects, improve product quality, and create a more effective and efficient BOPP production process at PT XYZ Tbk.