Reducing defective products using six sigma for production process improvement

Abstract

A good production process generates a good product that is free from defects. Therefore, understanding the defect level serves as an essential parameter in determining a good production process. One of the methods includes variation reduction by applying the concept of Six Sigma. This study aims to improve the production process and minimize defects by using the Six Sigma method with the DMAIC approach to obtain a process level setting that reduces product failure. Six Sigma is generally initiated with the stage definition, determining Critical to Quality (CTQ) continued by determining product improvement priorities. The measurement stage is conducted by calculating the DPMO and sigma values for the baseline performance. Then, in the analysis stage, determining defects factors is conducted by employing a Failure Mode and Effect Analysis (FMEA) method. Finally, the proposed improvement is determined by using the PDCA approach. The implementation results indicate an increase in the sigma value to 3.1 or an increase of 0.4.