Define, Measure, Analyze, Improve, Control Method Research Articles

Analisa Kecacatan Produk Air Minum Dalam Kemasan (AMDK) dengan Metode DMAIC di PT. Amanah Insanillahia

PT Amanah Insanillahia is a Bottled Drinking Water (AMDK) company that has been operating for a long time and prioritizes quality as a company strategy. There are various criteria for problems faced by the company, including quality problems in the production of drinking water in 240 ml bottles. Six sigma can be defined as a methodology that provides tools to reduce process variations and improve product quality using the DMAIC (Define, Measure, Analyze, Improve, Control) method. The purpose of this research is to determine the company's current sigma level and provide suggestions for improvements that suit the company. From the research results it can be concluded that there are 3 potential CTQs, namely imperfect cup, lack of water and machine pinching, with an average (CL) defect of 0.320, and an average DPMO of 106,476. The sigma level value is 2,77. Then the next stage is carried out by analyzing the causes of the cup not meeting standards, lack of water and being pinched by the machine. It is known that defect factors come from machine, material, method and human factors.

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

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%.

Implementation of Lean Manufacturing for Increasing the Quality of Aluminum Conductor Products in the Stranding Process with the DMAIC and VSM Method Approach: A Case Study in Electrical Manufacturing Component

ElectricalCompany in this study is a manufacturing company engaged in the cable industry and one of the products it produces is an aluminum conductor. The current situation shows that the quality of aluminum conductor products still does not meet thecompany's standards. This can be seen from the production output data for the period June 2021 –November 2021 where the percentage ofaluminum conductor product faiuresexceeds the set target of 1.50%. The purpose of this research is to implement lean manufacturing to improve the quality of aluminum conductor products using the DMAIC (Define, Measure, Analyze, Improve, Control) and VSM (Value Stream Mapping) methods. The expected result of this research is an increase in product quality.

Lean Six Sigma with Value Stream Mapping in Industry 4.0 for Human-Centered Workstation Design

Many industries have successfully implemented the define-measure-analyze-improve-control (DMAIC) method of Lean Six Sigma to improve their production activities. Value stream mapping (VSM) for Industry 4.0 allows us to understand the current state of operations in order to plan future improvements. In this study, we propose an improvement model based on DMAIC with VSM 4.0 for a truck cooler manufacturer to improve the picking workstation design with a human-centered approach. We use the DMAIC method to analyze the project step by step. After identifying the root cause, we identified countermeasures to improve the productivity. To reduce human error, the project team adopted a human-centered approach and applied lean tools, such as visual management, error prevention, and waste analysis. As a result of this case study, the yield rate was improved from 98% to 100%, and the direct savings of the project amounted to EUR 3180, mainly due to the freeing up of space. A human-centered LSS framework is also presented as a novel contribution of this study.

Define, Measure, Analyze, Improve, Control (DMAIC) Methodology as a Roadmap in Quality Improvement.

Define, Measure, Analyze, Improve, Control (DMAIC) Methodology as a Roadmap in Quality Improvement.

Analisis Quality Control pada Produk Omiland Kasur Bayi Untuk Meminimalisir Produk Cacat di PT. Wahana Kasih Mulia

Quality control is one of the obstacles experienced by PT. Wahana Kasih Mulia on CV. KKN. Quality control is an important thing that must be done by companies to minimize defective products. To be able to analyze product defects, researchers use the six sigma model, by formulating the Define, Measure, Analyze, Improve, Control (DMAIC) stages. The purpose of this study was to determine the level of quality control using the DMAIC method with the Six Sigma model applied to manufacturing companies. The results showed that from the measurement of the number of Omiland brand baby mattress products in the January-October 2021 period, it was found that defective products came from three main causes of disability. The distribution data of the number of product quality characteristics and company performance are at the sigma level of 3.50 with a DPMO value of 27,082.275. This shows that the company has not been able to meet process quality standards. Based on this research, the recommendations for improvement given are that the company needs to provide periodic training to employees, perform maintenance on machines, apply a clearer and more detailed Standard Operating Procedure (SOP), conduct tighter supervision of newly arrived raw materials and the company needs to place quality control at every stage of the production process.

Analysis of Aluminium Alloy Wheels Product Quality Improvement Through DMAIC Method in Casting Process: A Case Study of the Wheel Manufacturing Industry in Indonesia

The global market demand for automotive wheels with alloy materials is 55%, which is quite high compared to other materials such as steel, magnesium, chromed, and carbon fiber. The high competition of the global alloy wheels market demands to be able to offer quality alloy wheels. The purpose of this research is to reduce the number of defects in the casting process step by using the Define Measure Analyze Improve Control (DMAIC) method. This study shows the systematic approach to find the root cause of major defects in aluminum castings using the defect diagnostic approach as well as cause and effect diagram. Quality improvement using quality tools, namely the Pareto diagram, fishbone diagram. The major defects for the rejections during production were identified as leak defects, porosity motive holes, and oval defects. In determining the proposed quality improvements using the FMEA tool. The results of data processing on the calculation of process capabilities and product performance show improvements after quality improvements in the casting process. Product performance from DPMO = 15.462, sigma level = 3.6 to DPMO = 8.186 and sigma level = 3.9. The effect of decreasing the percentage of defects could save production costs by IDR 413.350.000. Therefore, the application of the DMAIC method can provide a significant improvement in product quality and impact on production cost savings.

Observation on the effect of DMAIC in reducing catheter-related urinary tract infection

Objective To explore the effect of DMAIC(Define, Measure, Analyze, Improve, Control) in reducing catheter-related urinary tract infection. Methods A retrospective case control method was used to select 578 patients admitted and treated in comprehensive ICU of Tianjin First Central Hospital from January to December 2018 with catheters as research objects.The 283 patients from January to June 2018 were the control group, and 295 patients from July to December 2018 were the observation group.Routine methods were used in the control group, and DMAIC method with 6 sigma management was used in the observation group. The correct rate of implementation of each measure, the utilization rate of urinary catheter and the infection rate between the two groups were compared. Results Implementation rate of early extubation assessment, urine collection accuracy, urine tube fixed correctly, urine tube cleaning time, urine collection bags location accuracy were 60.42%(171/283), 69.61%(197/283), 79.86%(226/283), 89.40%(253/283), 92.58%(262/283)in the control group, 80.34%(237/295), 90.85%(268/295), 94.92%(280/295), 96.27%(284/295), 97.97%(289/295) in the observation group, the differences were statistically significant (χ2= 9.411-41.415, P < 0.01). The rate of urinary catheter usage was 75.31%(3 856/5 120) in the observation group and 82.60%(4 098/4 961) in the control group, the differences was statistically significant (χ2=80.475, P < 0.01). The rate of catheter associated urinary tract infection was 0.26‰ (1/3 856) in the observation group and 1.95 ‰ (8/4 098) in the control group, the differences was statistically significant (χ2=5.832, P< 0.05). Conclusions DMAIC can improve the accuracy of nursing measures, optimize the catheter care process, and reduce catheter-related urinary tract infections. Key words: Intensive care unit; Indwelling catheter; Nursing care; Catheter-related urinary tract infection; DMAIC

Six Sigma application for quality improvement of the pin insertion process

Six Sigma is a systematic and organized, client-oriented approach that aims to improve the performance and quality of processes, products and services using statistical techniques. This paper presents a case study performed in an automotive company that intends to reduce the defective units produced by an automatic process, the process of single pin insertion, using the DMAIC (Define, Measure, Analyze, Improve, Control) method that is a structured way to carried out Six Sigma projects. In this process, excessive pin insertion force on Printed Circuit Boards (PCBs) entailed high rejection costs and line stop times that affected the supply of the final assembly lines. Therefore, the application of Six Sigma had the purpose to increase the quantity of products produced well at the first time and to reduce the quality costs associated to the process. To this end, the problem was defined, measured and analyzed starting from the machine and the two products with the highest number of rejections. An exhaustive analysis to determine the root cause allowed concluding that the excessive force is generated by the interaction of three factors: the PCBs physical characteristics, the pins contact zone and the wear of the machine components. A set of improvements focused on these factors raised the quality levels of the process, making it more stable and with less variability, by reducing the insertion forces to values closer to the nominal value. Methods for keeping the process under control were also defined and implemented. The use of some quality tools and the Six Sigma methodology proved to be extremely positive since this has led to significant improvements in the quality of the pin insertion process.

Six-sigma application in tire-manufacturing company: a case study

Globalization, advancement of technologies, and increment in the demand of the customer change the way of doing business in the companies. To overcome these barriers, the six-sigma define–measure–analyze–improve–control (DMAIC) method is most popular and useful. This method helps to trim down the wastes and generating the potential ways of improvement in the process as well as service industries. In the current research, the DMAIC method was used for decreasing the process variations of bead splice causing wastage of material. This six-sigma DMAIC research was initiated by problem identification through voice of customer in the define step. The subsequent step constitutes of gathering the specification data of existing tire bead. This step was followed by the analysis and improvement steps, where the six-sigma quality tools such as cause–effect diagram, statistical process control, and substantial analysis of existing system were implemented for root cause identification and reduction in process variation. The process control charts were used for systematic observation and control the process. Utilizing DMAIC methodology, the standard deviation was decreased from 2.17 to 1.69. The process capability index (Cp) value was enhanced from 1.65 to 2.95 and the process performance capability index (Cpk) value was enhanced from 0.94 to 2.66. A DMAIC methodology was established that can play a key role for reducing defects in the tire-manufacturing process in India.

Implementation of Six Sigma Method in Small and Medium Enterprises (SMEs) (Case Study on CV. Berkah Abadi)

The increasing economic growth in Indonesia encourages the growth of SMEs (Small and Medium Enterprises). This condition results in the intense competition among similar SMEs. This encourages companies to always produce quality products in order to meet customers’ satisfaction. One of the methods to control the quality is by using Six Sigma. Six sigma is a method of improving the quality towards the target of 3.4 failures per million opportunities for each production of goods and services. Six sigma is divided into two methods, namely DMAIC (Define, Measure, Analyze, Improve, Control) and DMADV (Define, Measure, Analyze, Design, Verify). Six Sigma can be implemented not only for big companies but also for SMEs. This study was conducted to determine the application of quality control aspect of Six Sigma in CV. Berkah Abadi as an SME in producing shoes under the name BNA. This study utilized DMAIC method. By using Six Sigma, it can be seen that the sigma value in the production process of CV Berkah Abadi is 3,274 with the possibility of error products contained is 38758.87 in a million occasions. In the application of Six Sigma in this study, there are six causes of defective products, namely untidy glue application (41.7%), stains (23.8%), squiggled pattern (11.9%), untidy stitches neat (10.4%), wrinkles (8.9%) and torn materials (2.9%).

IMPLEMENTASI PENERAPAN METODE SIX SIGMA PADA PROSES PERAKITAN ELEKTRO MOTOR (STUDI KASUS: PT. TATUNG ELECTRIC INDONESIA)

Tatung Electric Indonesia is a peripatetic company in manufacturing industry assembling of electro motor. So that product yielded by PT. Tatung Electric Indonesia can continue to fulfill requirement of customer, company try to improve the quality of its product by minimizing defect which during the time still happened. This defect arising caused by the existence of variation at yielded product and also that happened in the process. Six Sigma represent control technique or method to reach storey or level quality of 3.4 DPMO ( Defects Per Million Opportunities), which applied by Motorola company since year 1986. Applying strategy to be used is Define-Measure-Analyze-Improve-Control (DMAIC). This Method represent recuring step and form a make-up of quality cycle. Calculations show the company is 3.641 sigma level with DPMO 15,830. The sigma levels are on the average level of sigma industries in Indonesia (3-4 sigma). Increased levels of sigma would happen if the company immediately continuous improvement over time. Conclusion of the application of Six Sigma is the DMAIC method in the assembly process of electro motors can analyze and reduce disability that occurs that will increase the quality of products.

SU‐E‐T‐452: Identifying Inefficiencies in Radiation Oncology Workflow and Prioritizing Solutions for Process Improvement and Patient Safety

Purpose:Successful radiation therapy requires multi‐step processes susceptible to unnecessary delays that can negatively impact clinic workflow, patient satisfaction, and safety. This project applied process improvement tools to assess workflow bottlenecks and identify solutions to barriers for effective implementation.Methods:We utilized the DMAIC (define, measure, analyze, improve, control) methodology, limiting our scope to the treatment planning process. From May through December of 2014, times and dates of each step from simulation to treatment were recorded for 507 cases. A value‐stream map created from this dataset directed our selection of outcome measures (Y metrics). Critical goals (X metrics) that would accomplish the Y metrics were identified. Barriers to actions were binned into control‐impact matrices, in order to stratify them into four groups: in/out of control and high/low impact. Solutions to each barrier were then categorized into benefit‐effort matries to identify those of high benefit and low effort.Results:For 507 cases, the mean time from simulation to treatment was 235 total hours. The mean process and wait time were 60 and 132 hours, respectively. The Y metric was to increase the ratio of all non‐emergent plans completed the business day prior to treatment from 47% to 75%. Project X metrics included increasing the number of IMRT QAs completed at least 24 hours prior to treatment from 19% to 80% and the number of non‐IMRT plans approved at least 24 hours prior to treatment from 33% to 80%. Intervals from simulation to target contour and from initial plan completion to plan approval were identified as periods that could benefit from intervention. Barriers to actions were binned into control‐impact matrices and solutions by benefit‐effort matrices.Conclusion:The DMAIC method can be successfully applied in radiation therapy clinics to identify inefficiencies and prioritize solutions for the highest impact.

Decreasing laboratory turnaround time and patient wait time by implementing process improvement methodologies in an outpatient oncology infusion unit.

Prolonged patient wait times in the outpatient oncology infusion unit indicated a need to streamline phlebotomy processes by using existing resources to decrease laboratory turnaround time and improve patient wait time. Using the DMAIC (define, measure, analyze, improve, control) method, a project to streamline phlebotomy processes within the outpatient oncology infusion unit in an academic Comprehensive Cancer Center known as the Comprehensive Treatment Unit (CTU) was completed. Laboratory turnaround time for patients who needed same-day lab and CTU services and wait time for all CTU patients was tracked for 9 weeks. During the pilot, the wait time from arrival to CTU to sitting in treatment area decreased by 17% for all patients treated in the CTU during the pilot. A total of 528 patients were seen at the CTU phlebotomy location, representing 16% of the total patients who received treatment in the CTU, with a mean turnaround time of 24 minutes compared with a baseline turnaround time of 51 minutes. Streamlining workflows and placing a phlebotomy station inside of the CTU decreased laboratory turnaround times by 53% for patients requiring same day lab and CTU services. The success of the pilot project prompted the team to make the station a permanent fixture.

Reducing Liver Transplant Length of Stay: A Lean Six Sigma Approach

Organ transplant centers are under increasing scrutiny to maintain outcomes while controlling cost in a challenging population of patients. Throughout health care and transplant specifically, length of stay is used as a benchmark for both quality and resource utilization. To decrease our length of stay for liver transplant by using Lean Six Sigma methods. The Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) method was used to systematically analyze our process from transplant listing to hospital discharge after transplant, identifying many factors affecting length of stay. Adult, single-organ, primary liver transplant recipients between July 2008 and June 2012 were included in the study. Recipients with living donors or fulminant liver failure were excluded. Multiple interventions, including a clinical pathway and enhanced communication, were implemented. Length of stay after liver transplant and readmission after liver transplant.R ESULTS: Median length of stay decreased significantly from 11 days before the intervention to 8 days after the intervention. Readmission rate did not change throughout the study. The improved length of stay was maintained for 24 months after the study. Using a Lean Six Sigma approach, we were able to significantly decrease the length of stay of liver transplant patients. These results brought our center's outcomes in accordance with our goal and industry benchmark of 8 days. Clear expectations, improved teamwork, and a multidisciplinary clinical pathway were key elements in achieving and maintaining these gains.

An analysis of the Six Sigma DMAIC method from the perspective of problem solving

The DMAIC (Define-Measure-Analyze-Improve-Control) method in Six Sigma is often described as an approach for problem solving. This paper compares critically the DMAIC method with insights from scientific theories in the field of problem solving. As a single authoritative account of the DMAIC method does not exist, the study uses a large number of sources, consisting of prescriptive accounts of the method in the practitioner literature. Five themes are selected from the problem solving literature for the analysis of DMAIC—generality versus domain specificity of methods; problem structure; generic problem solving tasks; diagnostic problem solving; and remedial problem solving. The study provides a characterization of the types of problems for which DMAIC is a suitable method, but also identifies problems for which it may be ineffective. An important limitation of the method is its generality, which limits the methodological support it provides, and which fails to exploit task-domain specific knowledge. Domain-specific adaptations of the method partly overcome these weaknesses. Among the method's strengths are the powerful statistical techniques for fact finding and empirical verification of ideas, and the DMAIC stage model, which acts as a problem structuring device. The most prominent limitation identified in this study is Six Sigma's inferior methodology for efficient problem diagnosis. Methodological support for the identification of potential problem causes is offered as an incoherent and poorly structured collection of techniques, without strategic guidance to ensure efficiency of the diagnostic search. Adopters of the method should be aware of its potential limitations.

Metode DMAIC Sebagai Solusi Pengendalian Kualitas Produksi Sepatu Tambang: Studi Kasus PT Mangul Jaya-Bekasi

One way to increase profitability internally in PT Mangul Jaya - Bekasi is decreasing any costs produced from poor product quality by producing shoes with good quality. This study uses the DMAIC (define, measure, analyze, improve, control) method as a measuring tool. DMAIC is a quality improvement method that directly solves any problems related to the quality of a product even the primary cause of it. From the results of the study it is concluded that at the phase “define” shoes type Cheetah is the most problematic. Furthermore, on phase “measurement” it is identified that the Cp value of the Cheetah is below 1 which means that the process capability is low. After passing through the three sequencing steps (analyze, improve and control), finally this research is able to reduce the defects that occur in the shoes type Cheetah.

6시그마 기법을 활용한 도서관 정보서비스 개선방향에 관한 연구 - 해외 학술 및 전략 정보 구입 프로세스를 중심으로 -

With the environmental changes around libraries and information centers, they need to develop various management techniques and apply them to library works and services. In this research a case study was conducted in a special library of If company. This study was aimed for reducing ineffective components and unnecessary processes in library works and services. This study applied the Six sigma technique to improve the process of purchasing overseas academic and strategic Information and users` a degree of satisfaction on information service. Specifically, this study used the live-step DMAIC(Define, Measure, Analyze, Improve, Control) method, mainly used in the manufacturing sector. As a result of this study, we could get epoch-making improvement.