Analysis of Opaque, Peel-Off and Flex Rejects in the Electro Plating Process Using the Six Sigma Dmaic Method

Abstract

The modern manufacturing industry is faced with increasing pressure to achieve high levels of quality while remaining efficient in its production processes. One of the challenges faced by PT. Plating services in electroplating production have a high reject rate, which can cause increased costs and have a negative impact on the company's reputation. PT. Jasa Plating in the production process still has a high number of rejects, the rejects are dominated by opaque, peel-off and spots. PT. Plating services for each production contribute a high average of 2% defects per day, DPMO 20,000 and Sigma value 3.55. Quite a few rejections resulted in a decrease in turnover and increased production costs. The costs incurred due to these rejects are an average of Rp. 1,268,593 per day and an average of Rp. 35,698,907 per month as a result of data collection from January – September 2023. In this business process, this is very detrimental for the company. The aim of this research is to suppress blurry rejects, peel-offs and spots in the electro plating process at PT. Plating Services. The steps taken in conducting research include: identification stage, data collection and processing, analysis and recommendations for improvement, and conclusions. The method used in this research is the Six Sigma DMAIC (Define, Measure, Analysis, Improvement, Control) method. Through analysis, you can find several factors that cause high reject rates, including operational errors, discrepancies in the production process, or raw material quality problems. After implementing the improvement plan, then evaluate the results. This can include re- measuring the DPMO, analysis of the resulting products to see a decrease in reject rates, and comparisons between before and after implementing improvements. From the comparison results after the repairs were carried out, the data before the repairs were carried out, the NG amount was 1.99%, the DPMO was 6,646 and the Sigma value was 3.98. After improvements to NG 0.84%, DPMO 2,791 sigma value 4.28. Factors causing high levels of blurring, peel-off and spots, namely insufficient or excessive cleaning of the metal surface before the electroplating process, can cause problems such as peel-off. Contamination of the electroplating solution by foreign materials can cause blurring and flecks in the final layer. Machinery or equipment that is not properly calibrated, or experiences wear and tear, can produce products that do not meet standards. Variations in temperature, time, or electric current in the electroplating process can produce inconsistent coatings. Carefully monitor and control process-parameters to ensure stability.