Analysis of Cocoa Bean Quality Control Using The SIX SIGMA Method at PTPN I Kalirejo Plantation Banyuwangi

Abstract

PTPN I Regional 5 plays an important role in the development of the agricultural and plantation sectors, especially the Edel and Bulk cocoa types as its superior commodities. The problems faced are due to a decrease in production so that the quality of cocoa beans is not up to standard, non-uniformity and damage. The purpose of this study is to identify the types of defects and the number of defects, analyse the factors causing defective products, and formulate improvement proposals to reduce the number of defects. The methods used by Six Sigma include Define, Measure, Analyse, Improve and Failure Mode and Effect Analysis (FMEA). Production results in 2024 Edel Cocoa Beans were 3597 kg with 194 kg of defects. Meanwhile, Bulk is 5461 kg with 405 kg of defects. The types of defects are non-uniform size and hollow beans. DPMO value of Edel type is 26,966.92, final yield value is 97.31%. From the DPMO and final yield values, it is known that the sigma level is 3.5025. Bulk DPMO value 37,081.12, Final yield value 96.29%, From the DPMO value and final yield known sigma level is 3.3455. This shows the sigma capability of Edel and Bulk Cocoa Beans production has met the Indonesian final yield standard. The results of the FMEA analysis found 4 factors, namely raw materials, machines, methods and people.