INTEGRATING PDCA AND TF-6M AS AN ALTERNATIVE APPROACH TO ENHANCING PRODUCTIVITY IN THE MECHANICAL ENGINEERING TEACHING FACTORY

Firmansyah Sulistiyono; Rian Dwi Aji Saputro; Dadang Hafid

doi:10.17509/jmee.v13i1.95017

INTEGRATING PDCA AND TF-6M AS AN ALTERNATIVE APPROACH TO ENHANCING PRODUCTIVITY IN THE MECHANICAL ENGINEERING TEACHING FACTORY

Firmansyah Sulistiyono, Rian Dwi Aji Saputro, Dadang Hafid

Abstract

This study applies an integrated implementation of the PDCA and TF-6M methods within the Teaching Factory (TEFA) learning system through a digitally based classroom and industrial simulation concept. The integration of these two approaches was designed to overcome the limited alignment between vocational education and industry, particularly in terms of production process effectiveness and product quality control. Previous production reports in the Mechanical Engineering Teaching Factory indicated a 6 percent defect ratio. In addition, the absence of standardized material recording procedures led to discrepancies between incoming and outgoing material reports at the end of the production process. This research employed an applied action research approach conducted in the Department of Mechanical Engineering, involving supervising lecturers, technicians, and students participating in TEFA simulation activities. The study aimed to enhance productivity in Teaching Factory activities, especially those related to production processes. Key performance indicators included material reporting accuracy, workplace safety, product quality, and on-time delivery. The results indicate that the implementation of this system successfully established a more systematic, measurable, and efficient production workflow within TEFA activities. Students were able to comprehensively understand industry-based workflows, from production planning to product delivery to customers. Quantitatively, the application of the combined PDCA and TF-6M methods contributed to an 87.5 percent improvement in productivity. The product defect ratio (NG) decreased to 3.3 percent in the turning machining process, while in CNC milling all products achieved Zero NG with completion times exceeding the predetermined targets.

Keywords

Alternative; Continuous Improvement; Productivity, Teaching Factory; Mechanical Engineering

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DOI: https://doi.org/10.17509/jmee.v13i1.95017