Storage Rack Design to Minimize Customer Claims at PT Rekadaya Multi Adiprima Using DMAIC, FMEA, and NIDA Methods

Abstract

PT Rekadaya Multi Adiprima is a manufacturing industry that produces automotive components, especially for four-wheeled vehicles. PT Rekadaya Multi Adiprima is divided into four production divisions, namely the metal division, non-woven division, plastic division (service hole), and interior division. During the implementation of production at PT Rekadaya Multi Adiprima, there was still a customer claims process which was very detrimental to PT Rekadaya Multi Adiprima. Based on the results of interviews with quality staff, it was found that the number of claims occurring in 2022 at plant 1 of PT Rekadaya Multi Adiprima exceeded the tolerance set by the company, namely 0.05%. Based on these problems, further observations need to be made to resolve existing problems. The method used to solve this problem is the DMAIC (Define, Measure, Analyze, Improve, control) method with the help of the FMEA (Failure Mode and Effects Analysis) method based on customer claim data from July 2022- December 2022. The defining stage is carried out by analysis to determine product with the highest level of claims, the measurement stage involves calculating the DPMO value and Sigma Level, the analysis stage aims to find out the cause of the claim using the help of a fishbone diagram and the FMEA Table, in the improv stage the aim is to find and make improvements with the help of the 5W+1H Table based on the diagram fishbone and FMEA tables that have been made previously. As well as carrying out design using the NIDA method, the final stage of control is monitoring the expected improvement results. The results before the improvement, the DPMO value was 77,000 units with a sigma level of 2.925 and after the improvement the DPMO value decreased to 17,400 units with a sigma level of 3.611. The results of the improvements made reduced the level of customer claims by 61.93%.