Tugas Terstruktur 7 (Rencana Operasional dan Prosedur Pengendalian Mutu Usaha)

Rencana Operasional dan Prosedur Pengendalian Mutu pada Produksi Healthy Bite :Brownies Pisang Oat Rendah Kalori sebagai Makanan Diet Sehat

(Oleh Erlintang Mardika AE32)

Deskripsi Produk

Healthy Bite adalah brownies pisang oat rendah kalori yang diformulasikan untuk mendukung gaya hidup sehat dan program diet. Produk ini memadukan pisang alami sebagai pemanis utama dan oat sebagai sumber serat, sehingga menghasilkan brownies dengan rasa manis alami, tekstur lembut, dan kandungan kalori yang lebih rendah dibandingkan brownies pada umumnya.

Selain menonjolkan cita rasa yang lezat, Healthy Bite juga mengutamakan keseimbangan nutrisi, tanpa bahan pengawet, tanpa tepung terigu, dan tanpa gula rafinasi. Dengan konsep “guilt-free dessert”, produk ini menyasar konsumen yang ingin tetap menikmati makanan manis tanpa mengorbankan kesehatan.

Proses Produksi 

1. Persiapan bahan baku: Pisang matang dikupas dan dilumatkan, oat digiling menjadi tepung halus.

2. Penimbangan bahan: Semua bahan ditimbang sesuai resep.

3. Pencampuran adonan: Pisang, oat, telur, minyak zaitun, madu/stevia, dan bubuk coklat dicampur hingga merata.

4. Penuangan adonan: Adonan dituangkan ke loyang yang sudah dilapisi kertas roti.

5. Pemanggangan: Dipanggang pada suhu 170°C selama 30–40 menit.

6. Pendinginan dan pemotongan: Brownies didinginkan, lalu dipotong menjadi beberapa porsi.

7. Pengemasan: Setiap potong dibungkus dengan kemasan food grade berlabel Healthy Bite.

Perencanaan Kapasitas Dan Jadwal Produksi 

Kapasitas produksi Healthy Bite direncanakan agar dapat memenuhi permintaan pasar dengan tetap menjaga kualitas dan efisiensi kerja. Dalam satu kali produksi (1 batch), diperoleh 20 potong brownies dengan waktu total proses ±2 jam (termasuk persiapan bahan, pemanggangan, pendinginan, dan pengemasan).

Setiap hari dilakukan dua kali produksi (2 batch) dengan pembagian waktu sebagai berikut:

• Shift pagi  : 08.00 – 10.00

• Shift siang : 13.00 – 15.00

Periode	Batch Per Hari	Produksi Per Batch	Total Produksi
Harian	2 batch	20 loyang	40 loyang
Mingguan (5 hari kerja)	10 batch	20 loyang	200 loyang
Bulanan (4 minggu)	40 batch	20 loyang	800 loyang

Jadwal Produksi Mingguan

Hari	Waktu Produksi	Jumlah Batch	Target Produksi	Keterangan
Senin	08.00–10.00 & 13.00–15.00	2	40 loyang	Produksi Reguler
Selasa	08.00–10.00 & 13.00–15.00	2	40 loyang	Produksi Reguler
Rabu	08.00–10.00 & 13.00–15.00	2	40 loyang	Produksi Reguler
Kamis	08.00–10.00 & 13.00–15.00	2	40 loyang	Produksi Reguler
Jumat	08.00–10.00 & 13.00–15.00	2	40 loyang	Produksi Reguler
Sabtu	08.00–10.00	1	20 loyang	Produksi tambahan atau pesanan khusus
Minggu	-	-	-	Libur dan perawatan alat

Alokasi Sumber Daya

Perencanaan sumber daya dilakukan agar proses produksi berjalan efisien, higienis, dan konsisten menghasilkan produk berkualitas. Sumber daya dibagi menjadi tiga kategori utama: tenaga kerja, bahan baku, dan peralatan produksi.

Tenaga Kerja

Jabatan	Jumlah	Tugas	Kualifikasi
Koki Utama	2	Menyiapkan resep,mencampur bahan, mengatur pemanggangan	Menguasai dasar pembuatan kue dan pengaturan oven
Asisten Produksi	2	Menimbang bahan, membantu pencampuran, membersihkan alat	Teliti dan disiplin kebersihan
Petugas QC Dan Pengemasan	2x2	Memeriksa kualitas produk, melakukan pengemasan, mencatat hasil produksi	Teliti, paham dasar kebersihan pangan

Total tenaga kerja : 6 orang

Jam kerja : 08.00 – 15.30 WIB (termasuk istirahat 30 menit)

Bahan baku utama dan tambahan 

1. Pisang Ambon
2. Rolled oat yang dihaluskan sebagai pengganti tepung
3. Telur ayam 
4. Stevia (Sebagai pemanis)
5. Cocoa powder
6. Minyak zaitun 
7. Baking powder
8. Almond / choco chips / Keju / kacang mete (sebagai topping tambahan)
9. Kemasan food grade + label 

Peralatan Produksi 

Peralatan	Jumlah	Keterangan
Oven listrik 40 L	2 unit	Untuk memanggang brownies
Mixer	2 unit	Mencampur bahan
Loyang brownies	10 buah	Cetakan Brownies
Timbangan digital	2 unit	Penimbangan bahan
Meja stainless	2 unit	Area kerja higienis
Sealer Plastik & Kemasan kotak	2 unit	Pengemasan produk

Layout Fasilitas Produksi

Fasilitas produksi Healthy Bite dirancang dengan konsep alur satu arah (one way flow) agar proses pembuatan brownies berjalan efisien dan higienis. Setiap area dipisahkan berdasarkan fungsi untuk mencegah kontaminasi silang antara bahan mentah dan produk jadi.

Alur kerja produksi 

1. Persiapan Bahan Baku
   Menimbang semua bahan seperti oat, pisang, stevia, telur, dan cokelat bubuk sesuai takaran resep.

2. Pencampuran Adonan
   Seluruh bahan dicampur menggunakan mixer hingga adonan homogen.

3. Pemanggangan
   Adonan dituangkan ke loyang dan dipanggang pada suhu 180°C selama ±35 menit.

4. Pendinginan Produk
   Brownies didiamkan di rak pendingin selama 20–30 menit sebelum dikemas.

5. Pengecekan Mutu (QC)
   Produk dicek dari segi warna, tekstur, aroma, dan rasa sebelum dikemas.

6. Pengemasan dan Labeling
   Brownies dikemas dalam kotak ramah lingkungan, diberi label nutrisi, dan segel keamanan.

7. Penyimpanan dan Distribusi
   Produk jadi disimpan di area bersuhu ruang kering dan dikirim ke pelanggan sesuai jadwal.

Estimasi Biaya Operasional

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Komponen	Jenis Biaya	Estimasi Biaya (Rp/Bulan)
Bahan Baku	Variable	5.520.000
Gaji Karyawan (6 0rang)	Tetap	9000.000 ( 1.500.000/orang)
Listrik dan air	Tetap	800.000
Kemasan dan label	Variable	1.200.000
Promosi dan distribusi	Variable	1000.000

Waktu Siklus Produksi

Kegiatan produksi Healthy Bite: Brownies Pisang Oat Rendah Kalori dilakukan setiap hari selama 2 jam, dimulai pukul 08.00–10.00 dan 13.00-15.00 WIB.Dalam periode waktu tersebut, tim produksi mampu menyelesaikan 2 batch brownies

Tahapan proses	Aktivitas Utama	Estimasi Waktu
Persiapan Bahan	Menimbang bahan baku, mencampur bahan kering dan basah	20 menit
Pengadonan & Percetakan	Mengaduk adonan dan menuang ke loyang	15 menit
Pemangangan	Pemanggangan pada suhu 180°C hingga matang	45 menit
Pendinginan & Pengemasan	Pendinginan, pemotongan, dan pengemasan produk	40 menit
Total Waktu Produksi	-	± 2 jam (2 batch)

Rancang Prosedur Pengendalian Mutu

Standar kualitas produk

Aspek	Standar Kualitas	Keterangan
Visual	Warna cokelat (dark choco), permukaan halus tanpa gosong, potongan seragam	Tidak ada retakan besar atau bagian gosong
Fungsional (Rasa dan tekstur)	Rasa manis alami dari pisang, lembut di dalam, padat, tidak berminyak	Menggunakan bahan rendah kalori (oat & stevia)
Keamanan	Bebas dari kontaminasi fisik, kimia, dan mikrobiologi	Bahan baku tersimpan di tempat kering, higienis, dan diberi label tanggal kadaluarsa

Tahapan inpeksi dan metode pengujian

Tahap Produksi	Objek Pemeriksaan	Parameter yang diuji	Metode /Alat Pengujian	Frekuensi Pemeriksaan	Penanggung Jawab
Penerimaan bahan baku	Pisang, tepung oat, telur, stevia, minyak zaitun	Kesegaran, warna, aroma, tanggal kadaluarsa	Pemeriksaan visual & penciuman	Setiap bahan datang	QC
Penyimpanan bahan	Seluruh bahan baku	Kondisi penyimpanan (suhu, kelembapan, kebersihan)	Thermometer ruang & checklist kebersihan	Setiap pagi	QC
Pengadonan	Adonan basah	Konsistensi tekstur, aroma, dan homogenitas	Pengamatan manual & uji visual	Setiap batch	Koki , Asisten peroduksi & QC
Pemanggangan	Adonan dalam oven	pemanggangan dan tingkat kematangan	Thermometer oven & uji tusuk (garpu)	Setiap batch	Koki & QC
Pendinginan	Brownies matang	Suhu permukaan & kebersihan area pendinginan	Thermometer permukaan, visual	Setiap batch	Asisten produksi
Pemotongan dan pengemasan	Brownies siap potong & kemasan	Ukuran potongan, berat bersih, kondisi kemasan	Timbangan digital, penggaris, visual	Setiap batch	Asisten Produksi & QC
Penyimpanan produk jadi	Produk dalam wadah penyimpanan	Suhu, kelembapan, dan tanggal produksi	Thermometer ruang & pencatatan log harian	Harian	QC

Sistem pencatatan dan pelaporan cacat

Jenis dan klasifikasi cacat produk

Kategori cacat	Deskripsi	Contoh kasus	Dampak terhadap produk
Minor deffect	Cacat ringan yang tidak mempengaruhi keamanan produk	Warna sedikit tidak merata, bentuk potongan tidak seragam	Masih bisa dijual dengan harga diskon
Major deffect	Cacat yang mempengaruhi penampilan atau rasa	Gosong sebagian, adonan kurang matang, berat tidak sesuai standar	Tidak dijual, konsumsi pribadi atau digunakan untuk uji coba
Critical deffect	Cacat yang mempengaruhi keamanan pangan	Kontaminasi benda asing, bau tidak sedap, bahan basi	Segera dimusnahkan dan dilakukan investigasi penyebab

Pelaporan produk cacat

Tanggal produksi	Kode batch	Jenis cacat	Jumlah produk	Penyebab	Tindakan korektif	Petugas QC
04/10/2025	EM-01	Warna tidak merata	4 kemasan	Suhu oven tidak stabil	Kalibrasi oven & pisahkan produk cacat	Erlintang
05/10/2025	EM-02	Kemasan rusak	3 kemasan	Plastik kemasan terlalu tipis	Ganti kemsan baru dengan bahan yang lebih bagus	Devona

Tindakan korektif dan preventif

Setiap kali ditemukan cacat atau penyimpangan dari standar mutu, tim QC akan segera melakukan analisis penyebab dengan metode sederhana seperti root cause analysis. Langkah pertama adalah menghentikan sementara proses produksi pada bagian yang terindikasi bermasalah untuk mencegah bertambahnya produk cacat. Produk yang terlanjur diproduksi akan dipisahkan dan diberi label khusus sebagai “Produk Tidak Sesuai”.

Selanjutnya, dilakukan tindakan korektif, yaitu perbaikan langsung terhadap masalah yang ditemukan. Misalnya, melakukan penyesuaian pada peralatan produksi, mengganti bahan baku yang tidak sesuai, atau memperbaiki teknik kerja operator. Setelah tindakan korektif dilakukan, QC akan melakukan pengujian ulang untuk memastikan bahwa hasil produksi sudah memenuhi standar kualitas.

Sementara itu, tindakan preventif dilakukan agar masalah serupa tidak terulang di kemudian hari. Langkah ini meliputi pelatihan tambahan bagi karyawan, pembaruan prosedur kerja, serta pengetatan pemeriksaan bahan baku. Evaluasi berkala juga dilakukan setiap minggu oleh tim QC bersama supervisor produksi untuk meninjau tren cacat dan menentukan langkah pencegahan lebih lanjut.

Peran tim QC dan pelatihan karyawan

Peran tim QC

Tim Quality Control (QC) memiliki tanggung jawab utama untuk memastikan setiap produk Healthy Bite: Brownies Pisang Oat Rendah Kalori memenuhi standar kualitas yang telah ditetapkan.
Peran dan tanggung jawab tim QC meliputi:

1. Melakukan pemeriksaan bahan baku untuk memastikan kualitas dan kesesuaiannya dengan spesifikasi yang ditetapkan.

2. Memantau proses produksi dari tahap awal hingga akhir agar sesuai dengan prosedur standar (SOP).

3. Melakukan pengujian produk akhir berdasarkan parameter tekstur, rasa, aroma, dan tampilan visual sebelum pengemasan.

4. Mencatat hasil pemeriksaan serta melaporkan setiap temuan penyimpangan kepada kepala produksi.

5. Memberikan rekomendasi perbaikan serta memastikan tindakan korektif dan preventif diterapkan dengan benar.

6. Melakukan evaluasi rutin terhadap efektivitas sistem pengendalian mutu dan mengusulkan peningkatan berkelanjutan (continuous improvement).

Pelatihan karyawan

Untuk mendukung efektivitas sistem mutu, seluruh karyawan, terutama yang terlibat langsung dalam proses produksi, diberikan pelatihan rutin yang berfokus pada peningkatan kualitas dan keselamatan kerja.
Pelatihan mencakup:

1. Pemahaman standar mutu produk, termasuk aspek visual, fungsional, dan keamanan pangan.

2. Pengenalan dan penerapan prosedur kerja standar (SOP) agar setiap proses berjalan konsisten.

3. Pelatihan penggunaan peralatan produksi untuk menghindari kesalahan dan kerusakan alat.

4. Pelatihan kebersihan dan sanitasi diri, seperti cara mencuci tangan, penggunaan masker, sarung tangan, dan celemek.

5. Simulasi penanganan produk cacat agar karyawan memahami langkah korektif yang harus dilakukan.

6. Evaluasi berkala terhadap kinerja dan kedisiplinan karyawan dalam menerapkan standar mutu.

Dengan adanya peran QC yang jelas serta pelatihan karyawan yang terencana, Healthy Bite dapat menjaga konsistensi rasa, kualitas, dan keamanan produk, sekaligus meningkatkan kepercayaan konsumen terhadap merek.

Pendekatan Berbasis data dan Prinsip Manajemen Mutu

Untuk memastikan mutu produk Healthy Bite tetap terjaga dan proses produksi berjalan efisien, digunakan pendekatan berbasis data dan prinsip manajemen mutu modern seperti PDCA dan Kaizen. Pendekatan ini membantu tim produksi dan QC dalam melakukan perbaikan berkelanjutan serta memastikan setiap keputusan diambil berdasarkan hasil pengamatan dan data nyata.

Pendekatan PDCA (Plan – Do – Check – Act)

Metode PDCA diterapkan sebagai siklus perbaikan berkelanjutan dalam kegiatan operasional dan pengendalian mutu:

1. Plan (Perencanaan)

   • Menentukan target produksi harian dan standar kualitas produk (rasa, tekstur, aroma, dan tampilan).

   • Menetapkan kebutuhan bahan baku dan tenaga kerja berdasarkan data penjualan dan kapasitas produksi.

2. Do (Pelaksanaan)

   • Melaksanakan proses produksi sesuai dengan SOP yang telah disusun.

   • Melakukan pemeriksaan awal bahan baku dan proses pengolahan.

3. Check (Pemeriksaan)

   • Melakukan inspeksi pada setiap tahap produksi dan pengujian produk jadi.

   • Mengumpulkan data hasil uji mutu dan membandingkannya dengan standar kualitas yang ditetapkan.

4. Act (Tindakan)

   • Menyusun tindakan korektif apabila ditemukan penyimpangan.

   • Melakukan evaluasi hasil dan menyesuaikan SOP agar lebih efisien dan berkualitas.

Konsep Kaizen (Perbaikan Berkelanjutan)

Pendekatan Kaizen diterapkan untuk mendorong budaya kerja yang berfokus pada peningkatan mutu secara terus-menerus. Penerapannya mencakup:

1. Melibatkan seluruh karyawan dalam memberikan saran untuk perbaikan proses kerja.

2. Melakukan evaluasi mingguan terhadap hasil produksi dan menemukan sumber penyimpangan.

3. Menetapkan small improvement goals seperti penghematan bahan, waktu, atau peningkatan konsistensi rasa.

4. Memberikan penghargaan bagi tim atau individu yang berkontribusi dalam peningkatan mutu.

Diagram alur proses

Kesimpulan dan Saran

Kesimpulan

Produksi Healthy Bite: Brownies Pisang Oat Rendah Kalori dirancang untuk menghadirkan camilan sehat yang rendah kalori namun tetap lezat. Melalui perencanaan operasional yang efisien dan penerapan sistem pengendalian mutu berbasis PDCA dan Kaizen, produk dapat terjaga kualitasnya dari bahan baku hingga distribusi. Dukungan tim QC dan pelatihan karyawan juga memastikan konsistensi mutu serta keamanan produk.

Saran

1. Menambah variasi rasa agar produk lebih menarik bagi konsumen.

2. Melakukan evaluasi mutu secara rutin untuk menjaga standar kualitas.

3. Meningkatkan promosi melalui media sosial agar jangkauan pasar lebih luas.

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