Apllication of Six Sigma and FMEA Methods to Improve The Quality of Laminated Tube Packaging

PT. ABC is a subsidiary of the JawaPos Group, founded in 1996, and is one of the companies in East Java engaged in printing and packaging. The products produced include magazines, books and newspapers. Of all the company's products, one of the most significant defects is found in newspaper products, which is 4% of the average newspaper production of 806.598 copies and produces a moderate defect of 22,743 copies in 2019. The research was conducted to analyze the sigma value and determine the factors of product defects and the impact of the defects to provide suggestions for product quality improvement. In this research, the method applied is the Six Sigma method and Failure Mode and Effect Analysis (FMEA), by implementing and carrying out the stages in the Six Sigma method, namely DMAIC (Define, Measure, Analyze, and Control). From this research, the results obtained are that the company has several newspaper product defects of 181,943 copies consisting of several types of product defects, including damp paper, blurred colours, shaded printing, asymmetrical printing, and running printing. The company is currently at the 4.04 sigma level, so corrective actions need to be taken to achieve six sigma levels. By applying the Failure Mode and Effects Analysis (FMEA) method, it can be seen that the most significant and most frequent product defect is the blurred colour defect. Therefore the recommended alternative solution for repairs is to check the ink and replace the ink with standard ink or have a lower density, perform regular and systematic machine checks, and provide further guidance on newspaper printing production standards to all operators involved.

<p><em>PT. ABC is a subsidiary of the JawaPos Group, founded in 1996, and is one of the companies in East Java engaged in printing and packaging. The products produced include magazines, books and newspapers. Of all the products that the company has created, one of the biggest defects is found in newspaper products, which is 4% of the average newspaper product production of 806.59 copies and produces a moderate defect of 22,743 copies in 2019</em><em>.</em><em> </em>I<em>n this research, the method applied is the Six Sigma method and Failure Mode and Effect Analysis (FMEA), by implementing and carrying out the stages in the Six Sigma method, namely DMAIC (Define, Measure, Analyze, and Control). From this research, the results obtained are that the company has several newspaper product defects of 181,943 copies consisting of several types of product defects, including damp paper, blurred colours, shaded printing, asymmetrical printing, and running printing. The company is currently at the 4.04 sigma level, so corrective actions need to be taken to achieve six sigma levels. By applying the Failure Mode and Effects Analysis (FMEA) method, it can be seen that the biggest and most frequent product defect is a blurred colour defect. So that the recommended alternative solution for repairs is to check the ink and replace the ink with standard ink or have a lower density, perform regular and systematic machine checks, and provide further guidance on newspaper printing production standards to all operators involved </em><em>w</em><em>ork</em><em>.</em></p>

This research was conducted at a logistics company engaged in warehousing and logistics services, or 3PL (third-party logistics service providers). Based on the results of the study, it is known that there are three types of product defects, the highest occurring during the last month, namely differences in pallet wood dimensions, cracks, and knots in pallet wood. From the FTA (Free Trade Agreement) diagram, it is known that the wood dimension product defect is a product defect that has the highest percentage of defects among other product defects, which is 62%. The processing results obtained an average DPMO value of 353.28 failures per one million, and the sigma level is around 3.33. Based on data analysis using Failure Mode and Effect Analysis, there are 3 product defects: dimensional differences, cracks, and knots on pallets. The main causes of product defects are checking goods from less careful suppliers, using damaged wooden pallets, and lacking lighting in the work area. Based on the analysis using SIX SIGMA and FMEA, quality improvement proposals for the company, namely conducting training and training so that employee knowledge and skills increase, selecting pallets that meet the standards, and adding lighting in the work area. Keywords: Defect, FTA, DPMO, Six Sigma, FMEA

PT. Yogya Presisi Teknikatama Industri (PT. YPTI) is a mold, precision part, and plastic injection maker company. One of the obstacles faced by the company is the high level of nonconformity on its production results. The waste on production process can be identified and classified into four types, i.e.: a). during the process of injection molding machines, b). finishing and cutting processes, c). quality control process and d). the packaging process. The objectives of this research are minimizing the defective goods and reducing the waste using Lean Six Sigma and FMEA approaches, especially for Bush product. From the analysis result, defective types on Bush product can be classified into bubble, speckle, short shoot, sunken, sink mark, over-cut, flashing, and discolor. Based on the attributes data on Bush product, the DPMO score is 988.42 or the sigma level is 4.6, While the DPMO score on the variable data on each dimension i.e.: a). Slit width on the bottom side has DPMO score of 30119 (sigma level 3.37), b). Diameter of the circle on the top side has DPMO score of 392294 (sigma level 1.77), c). Product thickness on the top side has DPMO score of 70474 (sigma level 2.97), d). Product height has DPMO score of 82107 (sigma level 2.89), product thickness on the bottom side has DPMO score of 24448 (sigma level 3.47), and f). Diameter of the circle on the bottom side has DPMO score of 24448 (sigma level 3.47). The highest RPN score on the dominant types of product defects which needs improvement are the defective goods of bubble type has RPN score of 729, flashing and the molten material out on the heating channel has RPN score of 384, over cutting has RPN score of 324 and sink mark has RPN score of 270. The recommendations for improvement that can be given from this research are making checklist for maintenance and production monitoring, enhancing work supervision and inspection, as well as improving the environment and work stations.

To maintain consistent quality of production results and as an effort to identify unexpected factors that cause the production process to not function smoothly, quality control is very important. The research questions answered are how much production output and level of defects in products at PT. Busana Indah Global for the 2022 period?; what is the Six Sigma level in the products produced at PT. Busana Indah Global?; What factors cause defects in products?; What are the suggestions for improving the causes of product defects to improve product quality? The data analysis method used in this research is the Six Sigma method. This method is used to anticipate the occurrence of errors or defects by using measurable and structured steps. From the results of quality control research using the Six Sigma method, it is hoped that companies will carry out quality control continuously and consistently to reduce the level of defect values in production and to increase the Six Sigma value.

Application of Six Sigma Dmaic and Kaizen Methods In Efforts to Improve The Quality of T-Shirt Isles Banana Seven Products in Textile Industry. Textile Industry Company is a company engaged in manufacturing that produces textiles and garments. The Textile Industry Company in producing isles banana seven t-shirt clothing has a problem, namely the relatively large number of defects in production. The percentage of company disability in producing isles banana seven t-shirt clothing can reach 13%. see problems in the Textile Industry Company company that has a high percentage of product defects. Researchers will conduct quality control with the six sigma and kaizen DMAIC methods to reduce the number of disabilities and control disability in companies in producing isles banana seven t-shirt products. Critical To Quality (CTQ) for the most defects in the product of banana seven t-shirt is 4, namely jumping stitches (25.15%), broken stitching (23.96%), gross (22.50%), and perforated (14) , 63%). The DPMO for the isles banana seven t-shirt is 24336 units with a sigma capability of 3.47-sigma. The results of the analysis in kaizen prioritize the need for periodic checks of all facilities used.

The company of this researchis one of the largest auto and motorcycle parts manufacturers in Indonesia. To support the productivity of demand from customers, Companyis divided into 2 plants, namely the Cikarang plant and the Karawang plant. While the production process is divided into several departments, one of these departments is production. In its duties, production functions to control production targets that have been set by the company and minimize rejects from production, with one of them producing K50 type Camshaft parts. Because in the Camshaft K50 part there are still many rejects, it is necessary to make improvements in the work process in order to create good effectiveness and efficiency. The percentage of reject reamer types that do not enter the pitch is 83%, drill blows 9%, and drill breaks 8%. Improving the quality of the K50 Camshaft is done using the DMAIC method. The purpose of this research. At stage D (Define) what is done is to determine the Critical to Quality (CTQ) tofind out what are the physical quality characteristics of the Camshaft K50. In the M (Measure) stage, measurements are made using a Pareto diagram to find out the highest frequency of defects which later need improvement. The expected result is to minimize product rejection.

Defective product is a product that has poor quality and do not meet the standart. This defective products can give a bad impact to company, such as high production costs and decreased image company. Several methods that can be used to improve the quality is Six Sigma DMAIC methodology, FTA, and FMEA method. This study is conducted for several purpose, they are to determine the value of sigma level on the process of sugar production in PT.PG. Krebet Baru, to determine the factors that cause defective products in the process of sugar production by the FTA method, and to make a suitable solution based on the FMEA defective causes. The process sigma level in PT.PG.Krebet Baru is 3.58. That value sigma level indicates PT. PG. Krebet Baru is a company that are still growing and need improvement. The primary cause of the defects in the production process is a factor of operator and machine. Mode of failure with the highest RPN at 210 is time for steam process is too long, so they need to install the equipment that can detect the water level on sugar. When this equipment is installed, the exact time for drying will be known and the amount of defective product will be decreased. Keywords : Defective Product, Six Sigma, DMAIC, FTA, FMEA.

The trend of good performance in the manufacturing industry continues to increase in line with high consumer demand. For this reason, the plastic manufacturing industry has to go the extra mile to meet market demand. However, it is constrained by the ability of production machines that risk interfering with product quality. The cutting machine is a plastic production machine at PT. XYZ, functions as a plastic cutter. Has poor performance with high product defects. The research was conducted to determine the factors causing the high product defects on cutting machines at PT. XYZ. This research method uses the DMAIC concept to determine the factors that cause product failure. It was concluded that product failure on cutting machines reached 3422 kg, the DPMO value reached 1335.67 indicating sigma level 4, which means that the quantity of product defects is moderate, the cause of high product defects is due to worn out machine conditions, shortage of spare parts, human error due to workload and lack of supervision. Evaluation and suggestions for minimizing product defects on cutting machines include implementing an apprenticeship system, making SOPs, imposing strict sanctions, tightening supervision, rejuvenating production machines and providing spare parts for production machines.
 
 Keywords—Cutting Machine, Defect, DMAIC, Plastic, Quality Control

This study aims to analyze and reduce the number of defective products (defects) in the process of quality receiving packing door armrest panels at PT XYZ using the Six Sigma method with the DMAIC approach (Define, Measure, Analyze, Improve, Control). The defect problem was found in the Plant 3 area which had an impact on the non-conformity of product quality received by customers. Data was obtained through direct observation, historical problem data, and cause analysis using cause-and-effect diagrams and 5 Why Analysis. The results of the Define stage showed that the dominant defect type was internal defects due to dust particles. At the Measure stage, it was found that 87.5% of defects originated from internal factors. Analysis was conducted by identifying the root cause through the DMAIC approach. The Improve stage includes implementing corrective actions such as improving checking methods, improving cleaning aids, and reviewing packaging standards. Monitoring was carried out at the Control stage for three months and the results showed that no more defects occurred after the improvements were implemented. This research shows that the DMAIC method is effective in identifying and reducing the number of defects in the packing process at PT XYZ.

Product quality has now become one of the main factors that every company must have to compete globally. One way is to reduce the number of defective products in the production process. This method is a continuous improvement effort made by PT Toyota Motor Manu­fac­turing Indonesia and companies engaged in the automotive sector that produces cars. One of the processes is packing roof panels whose output will be sent to importing countries where the number of re­quests per month is relatively high but still has a high defect rate. Based on production data and defect data for the January-February 2019 period, roof panel packaging production has a 1% -3% defect rate. This company must reduce the defect rate to achieve the com­pany target of zero defects. This study aims to improve the quality of the packaging process by minimizing the number of defective products. This study uses the Six Sigma method with DMAIC phases. This method has several phases, namely, Define, Measure, Analysis, Improvement, and Control. Corrective action to reduce product defects based on 5W + 1H is to formulate a repair plan at the upgrade phase, namely by making SOPs spraying anti-rust and supervising operators who produce roof panel packaging. The improvement results reduced the DPMO value from 33,500 units to 2,050 units and increased the sigma level from 3.33 to 4.37. The DMAIC phase effectively controls and improves product quality levels in the automotive industry.

Usaha Konveksi Susilawati is one of the businesses engaged in convection that produces t-shirts that still have problems with defective products in the form of messy stitches, asymmetrical seams, incomplete accessories, unclean t-shirts, and inaccuracies in size, so quality control is necessary with the six sigma method.. Research This aim is to improve the quality of cotton combed t-shirt production using the DMAIC stage. This research begins with making a project charter and collecting data. It was found that there were four data that were outside the control limits, so improvement was needed. After that, the data is continued by calculating the DPMO value is 8,1350.80 and converting it into a sigma level of 3.90. With this sigma level value, it can be said that this company is at a profit of 25-40% sales and only reaches 93.3% customer satisfaction level. The results of FMEA analysis with the highest RPN value are method factors because there is no clear SOP. At the improve stage using the 5W+1H method, Kaizen 5S theory and Poka Yoke. Based on the improvement plan, a proposal for improving the design of a new work SOP can be made. The control stage is carried out by re-testing the company's production data after implementing the proposed improvement. The results obtained are the DPMO value of 2,063.71 and converted to a sigma level of 4.37. This shows that the production quality of the Usaha Konveksi Susilawati’s clothing has increased after the implementation.

Competition in the business world is getting tougher, encouraging companies to improve and develop the quality of their production, the quality of the goods or services produced will affect the competition of a company. Making the production process more effective is something that companies must do to increase production results and can affect company costs. PT.GCE is a manufacturing company operating in the Sheet Metal sector and the production process takes place on a job order basis. In the production process, various deviations and obstacles often occur which result in products experiencing non-conformities, both in product form and processing time. The Six Sigma method is a business strategy that is considered capable of improving and maintaining a company's operational excellence. The results of calculations carried out using the DMAIC method in the Part End Plate production process obtained data on 0.048 defects in the non-conforming product category and 0.084 defects in untidy products, so it can be concluded that defects in Part End Plate products are below 3.4 defects out of a million opportunities. From the calculation results, it was found that the factors causing defects in the Part End Plate production process could be caused by several factors experienced, including machine and labor factors. It is necessary to propose improvements that can be made in an effort to reduce the level of product defects in Part End Plate products so that defects no longer occur in the product. Keywords: DMAIC, Manufacture, Quality Control, Six Sigma.

Green Leaf Threshing (GLT) plant is an upstream company from the tobacco industries. The GLT main processing is separate the lamina from the stem and also dry out the tobacco into safe storage moisture content. One of the problems in the GLT factory is the high frequency of refeed / rework / reprocess on defective products. High refeed frequency increases production costs and eliminates customer trust. The aim of this study is to reduce refeed frequency. Six sigma is a methodology that can be used widely in manufacturing companies and services for continuous quality improvement. The Six sigma DMAI framework is used to find out the problems and solutions. The root cause of refeed are determined using fish bone diagrams and 5 Whys tool. The ranks for improvement are determined from the RPN using FMEA Analysis. The suggested program for improvement are investing tool, repairing tool and training worker. The results of identification indicate that defects due to inappropriateness moisture content are the highest cause of refeed. The results of the improvement indicate an increaseing sigma level from 3.72 to 3,97. The DPMO also declined from 13,220 to 6,823. Increasing sigma levelprovides benefit of Rp. 20.530.760.

Abstract. UD Cantenan is an industrial company engaged in metal casting, especially made from Aluminum. This company is known to have quality control problems in the manufacture of lip handle products and canal parts. The result of this problem is defective products in the lip handle and canal parts. In this case, of course, the company will spend more to repair the product so that the company experiences losses. Companies need to find ways to reduce the number of defective products. In this study, the Six Sigma method was used with DMAIC (Define, Measure, Analyze, Improve Control) and TRIZ stages to analyze and provide solutions to improve problems that occurred in the company. Based on the research conducted, at the define stage there are 3 types of defects in the lip handle product and canal parts, namely small scratches, small pinholes, and asymmetrical patterns. Then the measure stage obtained the percentage of small scratch defects of 54.47%, small pinholes of 17.3% and asymmetrical patterns of 28.2%. The average DPMO score obtained is 25,720 with a sigma level of 3.45 which shows that UD Cantenan can be categorized as good for industry in Indonesia. Furthermore, at the analysis stage Based on the identification of causal factors using FMEA analysis, it is known that the biggest contributing factor to failure is operator error in the operation of the milling machine. Then at the improve stage, make improvement proposals based on obtaining the highest RPN value from the factors causing disability using the TRIZ method. And the last stage, namely control, is the result of proposed improvements that can be made by the company to solve problems to reduce the number of product defects that occur during the production process.