Analisis Pengendalian Kualitas Produk Side Frame Dan Bolster Terhadap Cacat Pengecoran Baja Menggunakan Metode Seven Tools Di PT Barata Indonesia. (Analysis of Product Quality Control of Side Frame and Bolster on Steel Casting Defects Using the Seven Tools Method at PT Barata Indonesia).

Armadani, Moh Andrey Rifki (2025) Analisis Pengendalian Kualitas Produk Side Frame Dan Bolster Terhadap Cacat Pengecoran Baja Menggunakan Metode Seven Tools Di PT Barata Indonesia. (Analysis of Product Quality Control of Side Frame and Bolster on Steel Casting Defects Using the Seven Tools Method at PT Barata Indonesia). Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

The steel casting industry plays a crucial role in supporting transportation and infrastructure sectors; however, production defects often lead to reduced product quality and increased rework costs. PT Barata Indonesia, as a manufacturer of railway components—particularly side frames and bolsters—continues to experience a high defect rate. Based on Quality Control data from March to August 2025, the average defect rate reached 23.16%, consisting of 26.4% defects in side frames and 21.1% in bolsters. The most dominant defects identified were crack and porosity, which contributed the most to product failures. This study aims to analyze the quality control of the steel casting process using the Seven Tools of Quality Control, including check sheets, histograms, Pareto charts, fishbone diagrams, control charts, and scatter diagrams. Data were collected through field observations, interviews, and QC reports over a six-month period. The findings indicate that dominant defects are primarily caused by inconsistent working methods, suboptimal machine conditions, and variations in material and molding quality. These defects result in an average rework cost of Rp 3,475,000 per month, consisting of Rp 2,050,000 (59%) for side frames and Rp 1,425,000 (41%) for bolsters. Recommended improvements include stricter control of pouring temperature, enhanced operator discipline toward SOPs, and routine maintenance of machines and molds. These actions are expected to significantly reduce defect rates and improve the overall quality of steel casting production

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