DPMO Value Research Articles

REDUCING THE NUMBER OF PACKAGING IN THE CODING PROCESS AT PACKAGING UNIT USING THE SIX SIGMA METHOD

Non-dairy creamer is a product made at PT. NDC as a substitute for milk or cream, which is a fat emulsion product. Krimer is packed with a 25kg small bag with an updated coding according to the lot, production time, production date, product name, and packaging date expiration date. Often there is an error in the packaging unit, especially at the coding stage with the wrong non-dairy creamer packaging code that causes packaging defects. The defects in packaging focused on the coding stage, have to be minimized. The research uses the Six Sigma method as a useful tool to increase productivity and product quality. With DMAIC Discussion (Define, Measure, Analyze, Improve, and Control). Through data processing and analysis using the DMAIC cycle obtained three types of packaging defects, namely cryptic code, double code and wrong code from the three defects obtained percentage value of cryptic code 63%, double code 44% and wrong code 42% and obtained an average value sigma 3.71 with a DPMO value of 13,553

Aplikasi Model DMAIC dari Six Sigma dapat Memperbaiki Kualitas Produk Kapur Aktif

The need for active lime for the industry is quite a lot, including as a raw material for the production process, management of its main industrial waste and as a filler because many elements of CaO are needed. The needs are still insufficient because the items requested are mostly not in accordance with the specter requested by the user and after all the producers still use traditional methods and their human resources are still low so that meeting consumer demand is very difficult. With the Six Sigma method, the DMAIC model is used to improve and improve the quality of continuous active lime products so as to improve quality and quantity in the hope that consumer needs can be met. Based on the results of testing in the field and making repairs in the production unit to fruition can reduce the value of DPMO in the month before repairs (January - March 2015) amounting to 159506 and in June to 11585 with a percentage decrease of 7.26%. Thus the increase in sigma value in April was 3.43 sigma to 3.77 sigma. if a comparison of rework cost recording is made, the amount of rework cost before repairs is 10.63% of the total production value (Rp. 12,242,000) and after repairs in June 4.63% (Rp. 5,672,000), the savings obtained from the company are 6% (Rp. 7.343689, -) for spending on rework costs. By applying the Six Sigma method the DMAIC model in the production process which always makes continuous improvements can increase profits on the part of producers.

Perancangan Pebaikan Kualitas Produk Baut dan Sekrup Menggunakan Metode Six Sigma dan Data Mining di PT. A

PT. A is a manufacturing company that manufactures bolts and screws in accordance with customer demand. This study aims to determine the type of dominant defect that causes a decrease in quality, the factors that cause disability and apply proposed improvements to reduce the level of disability. Improvements are made by using the Six Sigma method, namely the DMAIC stage and making a decision tree (decision tree) using the Data Mining application. Where for the DMAIC stage are: Define, Measure, Analyze, Improvement, and Control (DMAIC). At the define stage, it was found that the production process with the largest number of defects was in the process of heading with the number of defects exceeding the target of 600 PPM (parts per million) that had been determined by the factory during April - June 2017. The heading process was the most important problem focused on the research conducted. The results of identification of Critical to Quality (CTQ) for the characteristics of attribute defects in the production of bolts and screws in the heading process are head burry, head no center, head crack, and body scratch. The second stage is the measure stage, where the control used by statistical process control (SPC) for attribute data is using the P control map and is known to have a sigma 3.50 level with a DPMO value of 22,727. The third stage is the Analyze stage, analyzing the problems of the four types of defects using the Ishikawa diagram. The improvement stage resulted from the decision tree in data mining processing that is obtained by standardizing inspections with seven IF THEN RULE functions, and making maintenance activity plans in the heading process. After implementation, there is a control stage, the results of the analysis show that after implementation using the data mining method and the Six Sigma method, the sigma value has increased which was originally 3.50 to 3.67.

Analisis Kualitas Distribusi Air Menggunakan Metode Six Sigma DMAIC Pada Pdam Surya Sembada Kota Surabaya

PDAM Surya Sembada Surabaya is a water supply company. This company distributes and supplies hygienic water to all residents in Surabaya. PDAM Surya Sembada Surabaya always tries to make customers satisfied with the provided services. Moreover, the company also tries to continue the improvements based on the management quality of ISO 9001: 2008. However, in the process of water distribution, some customers are still complaining due to the PDAM’s service, which indicates that not all the customers are satisfied. It is the duty of PDAM Surabaya to improve the quality services. This study focuses on providing the causes defects analysis of PDAM Surabaya Surya Sembada water distribution using the Six Sigma DMAIC. This study used descriptive qualitative approach with an emphasis on the question of how. The results of the research proved that there are two defects in the water distribution change into CTQ; defect TDA (No Water) and IMR (stench muddy water). In 2015, performance of Surabaya PDAM Surya Sembada showed the DPMO value as 844 and the value of capability sigma as 4.64. Based on Pareto diagram, this study stated that the dominant defect is TDA. This study applied the basic cause effect diagram to show the defect cause problem and used FMEA as a recommendation for continuous improvement that is expected to achieve zero defects. 
 Keywords: Six Sigma, defect, DMAIC, DPMO, value of capability sigma, CTQ, Pareto charts, cause and effect diagram, FMEA.

Six Sigma Application on Cement Packing Quality Control and Analysis to Reduce Defect

Quality control is applied to achieve company’s vision to be a distinguished cement company in south east region. The objective of this article is to analyze the process quality control and assign six sigma methods to do so. It results 4.44 sigma with DPMO value of 1,638.6 which shows that the company is within USA average performance in similar industry. In addition, this article identify the CTO priority is the damaged sack. The causes of this damage are coming from factors such as methods, machine, human, environment and materials. Considering its urgency, failure mode that need to be prioritized are censors, cut belt conveyor, filling tube, saddle back. The remedial efforts for such failures are: (1) Consistently supervise workers; (2) routine check on packer machines; (3) develop standard operating procedures; (4) machines maintenance; (5) employee training.

Usulan Perbaikan Kualitas Produk Pipa Api 5L PSL2 Menggunakan Metode Six Sigma

The production process of API 5L PSL2 pipes in Pipe Companies in 2017 happened to defect products at 7%. This defect is still above the standards set by the Company at 4%. The study aims to determine the value of sigma and provide recommendations for improvement with the six sigma method. Based on the results of the DMAI analysis, the amount of the pipe sigma level was 3.65 with the value of DPMO 14448. Types of defects identified in the process such as open welding defects, high lows, contact marking, scarring, and under dimension Proposed improvements were made by designing recommendations for improvements using 5W + 1H by checking the condition of the forming machine and changing bearing components before the bearing lifetime, performing preventive maintenance every week and adding coolant bursts to the cutting tool.

Usulan Pengendalian Kualitas Produksi Benang Carded dengan Metode Six Sigma

A yarn company strives to produce good and quality products, but the production process that is carried out by each person will produce products targeted at a target that has been set at 5%. This study uses the Six Sigma method but only until the improvement stage. The research is to determine the DPMO value and sigma level in the spinning production process, to know what factors cause defects and new parameters to reduce the defect. Based on the results of the study that the DPMO on the type of CD thread in the spinning section is 17,130 and the sigma level is 3,6. The level of sigma that has dominated the Indonesian industry average, but has a defect of 8.7%, the target set at 5%. Damaged and dirty apron, clogged trumpet, and leaky hose are factors that plan defects. Furthermore, with Failure Mode Effect Analysis (FMEA), the highest value of Risk Priority Number (RPN) in tangled defects is that the apron is damaged (140) and clogged trumpet (120), while the highest RPN value is gross dirty, i.e., dirty apron (150) and hose leaking lubricant (120).

APLIKASI PENDEKATAN SIX SIGMA UNTUK PERBAIKAN KUALITAS PADA PROSES PEMBUATAN TANK WASHER

PT. Laksana Teknik Makmur is a manufacturing company engaged in the manufacture of car accesories in Indonesia. One of the products produced is a tank washer with a high defect rate in the production process of 11 percent. This study uses the DMAIC method (Define, Measure, Analyze, Improve, Control) as a tool to solve problems about improving the quality of the process of making tank washer. The initial analysis for Define shows that CTQ (Critical to Quality) is the largest defect of the wave, which is 4.1 percent of the total defects of tank washer. From the measurement results in the Measure stage, the DPMO value is 108475 with Sigma Level 2.73. Then Analyze is done to get any factors that cause wave defects. On the Improve stage using Ishikawa's method, the results of the new Standard Operating Procedure are recommended. In the final stage, Control is carried out after the implementation of the new SOP for 1 month, the result is that the wave defect value drops to 2 percent and the Sigma Level value increases to 3.326 with the value of DPMO 20424.

Penerapan Metoda Six Sigma DMAIC untuk Mengurangi Cacat Pakaian 514 (Studi Kasus di CV Jaya Reksa Manggala)

<em>CV Jaya Reksa Manggala (JRM) is one of clothing company. With increasing competition in this clothing company, the companies are required to keep improving the quality of clothing products. One of the important things in quality is reduction of product defects. One of the proven methods of quality improvement is the Six Sigma DMAIC method, which is a continous improvement method that aims to achieve the best quality. One of the products of CV JRM which is still have a lot of defects is 514 products. From the initial data obtained, DPMO value for process I and II for 514 products is 10,768.52 and 27,341.42 with sigma level 3.79 and 3.43. The steps undertaken in this Six Sigma DMAIC method include define, measure, analyze, implementation and control. Several proposed improvements were then made to reduce the problem of these defects and from the data at the control stage, the DPMO values of processes I and II became 2,941.76 and 1,812.69 with sigma levels of 4.25 and 4.41. From this result it can be said that with Six Sigma DMAIC method, there is improvement of quality for product 514 at CV JRM. </em>

IMPROVING CONSUMER SATISFACTION BY INTEGRATING ON SERVICE QUALITY AND LEAN SIXSIGMA METHODS

Service quality (SERVQUAL) is one method that can be used to measure customer satisfaction for services that have been received that is by comparing the level of perception and expectations. Lean, six sigma is a method or technique for controlling and improving the quality of which is a dramatic breakthrough in the field of quality and is always oriented to customer satisfaction with a measurement target of sigma quality level. Integration SERVQUAL and Lean Six Sigma methods aims to SERVQUAL measurement results were analysed is to determine the critical variables, followed by calculation of DPMO and sigma value of the critical variables that can be known variables thatpriority improvements.

Analisis Pengendalian Kualitas Super Absorbent Polymer Dengan Menggunakan Metode Six Sigma

Quality control is an effort to increase customer satisfaction and minimize damage. Super Absorbent Polymer which is a product as a raw material for making baby diapers / elderly and sanitary napkins. In Super Absorbent Polymer, defects usually found in the colour contamination that there is a dark colour on the product, print labels mistakes and packaging defects. This study aims to determine the value of DPMO and sigma level, identify the efforts which is taken to reduce disability, identify the types of disability, and find the main factors causing disability. Six Sigma method is used to analyze data with define, measure, analyze, improve and control. The quantitative data obtained by direct observation of quality problems. By using the method of six sigma can be seen that the quality of the resulting product is quite good that is 3.07 sigma with a damage rate of 58,624 for a million production (DPMO). The three highest defect product causes are color contamination of 93.34%, misprint of 3.55%, and packaging damage as much as 3.11%. The main factor causing defects is the engine factor for the type of colour contamination defect,. The type of improper defects in the packaging labels and main factor for the packaging defects is the human factor.kecacatan rusaknya kemasan faktor utama ialah faktor manusia.

ANALISIS PENGENDALIAN MUTUCPO (Crude Palm Oil) MENGGUNAKAN SIX SIGMA DI PABRIK PENGOLAHAN CPOPT. GUNAJAYA KARYA GUMILANG KECAMATAN KENDAWANGAN KABUPATEN KETAPANG

The purpose of this research is to identify the quality of CPO in the palm oil Factory at PT Bumitama Gunajaya Agro. The analysis was carried out by processing the data of free faty acid, water level, and impurity level. Descriptive analysis was applied in this reaserch by using six sigma the use of six sigma aimed to identify if the quality which was produces by the company has relied on the standard wanted by the consumer.The result reported that the quality of free faty acid remained at level of 1,3 sigma with DPMO value 317500 products that were underqualified as decided by SNI. The improvement that can be applied as in fish bone diagram was to the human resources, the propellents, and the machines. The analysis result at water quality sigma level has been at level 3 of sigma but with DPMO value by 2700hence, having analysed by Fish Bone Diagram, machinery was the factor that sould be improve in order to improve the sigma level. Meanwhile, impurity content has approximentely reached level 4 sigma, in this case reaching the company’s target that expect the CPO quality above 3 level sigma. Therefore, at impurity content, it was unnecessary to find the problem about the quality inapporiateness with the consumer’s standart (SNI).

PERENCANAAN PENGENDALIAN KUALITAS BATU BATA DENGAN MENGGUNAKAN METODE SIX SIGMA PADA UD. X

The quality of goods or services is one of the factors that influence the consumer's attention. Improvements to the quality of the production process is done continuously to minimize product defects, one method that can be used to control the quality and overcome the number of defective products is with the Six Sigma method. From the calculations, the defective products caused by 3 decay, which amounted to 9520 due to a broken, 7598 defects due to underdonebricks and about 6,740 defects due scorched. Percentage of bricks defective to total of production is about 36%. This percentage is huge, given the controls used is 1%. From the causals diagram, there are factors that affect the defective products which are human, the burning process and materials. By using six sigma obtained DPMO value of 124,888.23 and the number six sigma of 2.69.Keywords: Six sigma, quality, defective products.

Peningkatan Kualitas Knalpot Pada Pt Fajar Indah Menggunakan Metode Six Sigma

PT Fajar Indah is an automotive company which is one of their flagship products is muffler for Colt Diesel FE 120 PS. During 2012 and 2013, PT Fajar Indah was able to produced muffler up to 2400 unit with 6-7% defects rate. There are five type of defects that affects muffler’s quality which are lid’s defects, ring’s defects, defects of resonator’s size, defects of plate’s cutting size, and defects of broken plate. To determine whether improvements are needed in muffler’s prodution process and how they will be conducted so six sigma will be used for analysis. Analysis was conducted using DMAIC process, where recommended action for quality improvement were determined with RCA and FMEA. Result from analysis shows that PT Fajar Indah had 12,879 DPMO value and 3.73 sigma which mean that improvement is needed in muffler’s production process. Some recommended actions that can be done are maintenance scheduling, making work instruction and supervise it, improving storage method for ring’s model, provide place for plate scraps from cutting process, adding more workesr for products inspection, and looking for suppliers who are able to provide plate with standard quality.

Sistem Informasi Kinerja Layanan Laboratorium Medis dengan Metode Six Sigma

Medical Laboratory currently holds a very important role in medicine. Evaluation of laboratory quality plays a very important to maintain accurate laboratory results. This study aims to design an information system performance based on the same perception of medical laboratory services from customers using Six Sigma methods and frameworks using ServQual questionnaire. Selection of Six Sigma itself is based on this method can measure the extent to which each process deviates from its purpose as well as to reduce the variation of each of the attributes. Six Sigma DMAIC namely (Define, Measure, Analyze, Improve, Control) preferred because the end result will not yield new products, but only improvements on existing processes. The results of this calculation will be presented in the form of a dashboard for easier management in understanding the results of the evaluation. From the system can be obtained an average value of consumer perceptions terhdap performance today is 2,883, consumer expectations on the performance of 3.3768, the gap between the perceptions and expectations of consumers is -0.4936, customer satisfaction will be the performance of the current 85.37%, the value of 423 360 DPMO and sigma value there at the 2.07664 level.

Rancangan Sistem Informasi Pengendalian Kualitas Produk Barrel pada PT OneJect Indonesia dengan Metode Six Sigma

PT OneJect Indonesia faces the high level of defect on its barrel products. To overcome this problem, this study proposes an application quality control based on information system. We implement requirement analysis based on the needs of quality control methods, while to lower the defect rate we utilize Six Sigmamethod with DMAIC (define, measure, analyze, improve, control) phases. In define phase we determine the type of product to be investigated using Critical to Quality, as well as the problems and objectives. In measure phase we calculate DPMO value and sigma level; sigma value of 3.520 is obtained. Then we calculate P control chart to see the production process control. In analyze phase we create pareto diagram to see the types of dominant defects. Then we create cause-and-effect diagram to determine the cause of defects, and five whys diagram to determine the root causes of the defects. In improve phase, we do improvement analysis through FMEA table by calculating the RPN value to determine the failure modes to be controlled. In control phase, we implement the proposal and simulation of sigma value increase. The analysis and design uses object-oriented information system by Lars Mathiasen, and UML as the requirement modeling and the design system. The results obtained are the documents of top-level analysis and design of information system as a quality control material for the actual system development.

USULAN PENERAPAN METODE SIX SIGMA UNTUK MENGURANGI TINGKAT KECACATAN PADA PROSES PRODUKSI PIPA API 14 INCH DI PT BAKRIE PIPE INDUSTRIES

PT. Bakrie Pipe Industries is a company engaged in the production of steel pipe. Pipe -steel pipe produced by PT. Bakrie Pipe Industries is used for a variety of needs such as: pipes foroil and gas , for the installation of water pipes, pipes for construction purposes, and for otherpurposes. PT. Bakrie Pipe Industries always maintain the quality of the resulting production andefforts to minimize the failure existing production of the company's. Therefore, Do research usingthe six sigma method with methodology DMAIC (Define, Measure, Analyze, Improve, andContorol) expected by using this method can minimize the defects and also improve the speed ofproduction.In the define stage, the selection of products to research the specs API steel pipe with14-inch size that has defects percentage of 5.25% and therefore this product the focus ofresearch.Furthermore the Measure stage is measurement sigma level company, the results of thesemeasurements show the value of 26,285 DPMO with sigma level was 3.44 sigma that indicates thatvalue still far from the target of 6 sigma.The next stage is a Analayze stage to analyze the causesof production failure that occurred in production, using Ishikawa diagram and FMEA tables.Thenthe Improve stage is giving suggestions for improvement and suggestions given for companay with:the application of methods of DOE (Design Of Experiments) with factorial 21 to find the optimaldistance in screw machine, giving proposed a tool is Roll Waterpass and application formmonitoring for the surveillance for removing the beads process. After do some implementationsgained increasing value 21,662 DPMO and sigma value of 3.52 sigma.

Perencanaan Peningkatan Kualitas dengan Menggunakan Integrasi Metode Six Sigma dan ISO 9001:2000

Companies who produce several of cigarettes, one of the kinds is BM Universal 12. To produce product with best quality and due to give satisfaction toward its consumer, there are several problem faced by the cigarette production process which is there are still defect product in its production process. From this condition, they need one method to deal with the matter. Using six sigma methods, they can identify defect product and by doing that they could improve the quality of the product. In this experiment it's using integration method by combining six sigma method and ISO 9001:2000. Six sigma methods is expected to be able minimizing the defect in PT "X" by creating production process more effectively, better performance of the company and still fulfilling the need and the satisfaction of the consumer while also making efforts to improve and inclined its quality. Meanwhile ISO 9001:2000, is an international standard that has orientation toward the qualifying products. Based on its internal data and observation commence inside the company, there would be only three main clauses from ISO 9001:2000 requirements that is going to be made as measuring points of product quality improvement, which is clause 5 (management responsibilities), 7 (product realization) and 8 (measurement, analysis and improvement). While Six Sigma phase comprises of Define, Measure, Analyze and Improve. In Define phase there would be defining the product, the making of Six Sigma team and the making of production flow process. Measure has 3 kind defects that usually have bigger percentage than other defects which is unbalance weight defect (including empty shell) and korep defect. The percentage that goes with unbalance weight defect (including empty shell) is 41.9% and korep defect with 21.03% from all three defect we gained DPMO value reaching 7776 and sigma level reaching 3,9. By viewing the FMEA and RPN, the improvement alternatives that suppose to be done by the company is creating job instruction, implementing job instruction in rolling process then the company should be able to save Rp3,942,975.00 for one month.