Analisis Pengendalian Batter Pick Up Produk Nugget Ayam di PT XYZ | Analysis of Batter Pick Up Control for Chicken Nugget Products at PT XYZ

Nugget ayam adalah olahan daging ayam yang digiling dan dibumbui, kemudian diselimuti oleh perekat tepung, dibalut dengan lapisan tepung roti dan digoreng lalu dibekukan untuk mempertahankan mutunya selama penyimpanan. Dalam proses pelapisan nugget ayam (pick up) masih fluktuatif sementara standar perusahaan harus tercapai di 17,89± 0,61%, proses pelapisan ini sangat dipengaruhi oleh konsistensi viskositas batter yang tidak stabil. Berdasarkan acuan dari Performance Measurement System (PMS) PT XYZ (2024), produk nugget ayam memiliki kenaikan berat bobot produk pada proses pelapisan menjadi sebesar 106-112 gram/9 pcs atau dalam persentase kenaikan bobot produk sebesar 17,89± 0,61%. Dalam mencapai target persentase kenaikan bobot produk melalui proses battering, dilakukan kajian untuk mengendalikan faktor-faktor yang berpengaruh terhadap viskositas menggunakan metode Plan, Do, Check, Action (PDCA) dan diagram Ishikawa di PT XYZ. Perbaikan dilakukan dalam mengatasi permasalahan inkonsistensi kenaikan bobot produk, viskositas adonan yang tidak stabil, penurunan bobot produk setelah mesin air cutter, dan terdapat bagian nugget yang tidak terkena adonan. Perbaikan ini menghasilkan standarisasi One Point Lesson (OPL) metode pembuatan batter yang sesuai untuk mencapai target persentase kenaikan bobot produk. Melalui tindakan perbaikan pada bulan Oktober 2024 persentase kenaikan bobot produk nugget ayam setelah proses pelapisan mencapai 17,90±0,88% dibandingkan dengan bulan Agustus 2024 sebesar 16,67±3,16%. Kenaikan persentase pick up sebesar ±1,26%, berpotensi dalam penghematan biaya produksi dari hasil tindakan perbaikan dalam kurun waktu satu tahun yaitu sebesar Rp374,977,384.5.

Chicken nuggets are processed chicken meat that is ground and seasoned, then coated with flour adhesive, wrapped in a layer of breadcrumbs and fried and then frozen to maintain its quality during storage. In the process of coating chicken nuggets, there are several problems that can arise, including the pick up of chicken nuggets is still fluctuating while the company standard must be achieved at 17,89± 0,61%, this coating process is greatly influenced by the consistency of the unstable batter viscosity. Based on references from PT XYZ (2024), PMS (Performance Measurement System), chicken nuggets products have an increase in product weight during the coating process of 106-112 grams/9pcs or a percentage increase in product weight of 17,89± 0,61. In achieving the targeted pick up percentage, a study was conducted to control the factors that affect viscosity using the Plan, Do, Check, Action (PDCA) method and the Ishikawa diagram at PT XYZ. Improvements were made to overcome the problems of inconsistent product pick up, unstable batter viscosity, decreased product pick up after the air cutter machine, and there were parts of the nuggets that were not exposed to the batter. This improvement resulted in the standardization of One Point Lesson (OPL) batter making method that is suitable for achieving the targeted pick up of chicken nugget product. Through corrective actions in October 2024, the pick up percentage of chicken nugget products after the battering process reached 17,90±0,88% compared to August 2024 which was 16,67±3,16%. The increase in the pick up percentage of ±1,26%, turned out to have the potential savings in production costs from these corrective actions within a period of one year amounting to Rp374,977,384.5.