Minimize the potential failures in the wire rod production process using six sigma and multi attribute failure mode analysis method

Abstract

Wire rod mill (WRM) plant is one of the factories in Company X that produces wire rod. In 2018 and 2019, WRM was recorded producing high quantity of rejected product exceeding the set standard. This study deploys systematic problem identification and improvement to the process. The methods used was Six Sigma method to evaluate current condition and process capability, followed by Multi Attribute Failure Mode Analysis (MAFMA) with Grey AHP approach to identify root cause and weighted failure process that will be put into priority of improvement. Based on the research results, the sigma value obtained is 4.297503 o with DPMO value is 2,928.626. Improvements to the five highest of the causes of process failure is to improve the state of bearing roll, roll entry, hydraulic valve, an improvement on roll adjustment and improvement of inter-roll partings. It was concluded that the potential causes that the hot button bearing roll has the highest weight is 0.94569, so making it a top priority improvement.