DPMO Value Research Articles

Eliminating Production Process Waste with Lean Six Sigma in the Gresik Ceramic Industry

The Gresik Ceramic Industry is a company operating in the ceramic industry. In the ceramic production area at PT XYZ, waste is still found, namely waste defects, safety health environment (SHE), excess processing. and motion. This research aims to identify and reduce waste in the ceramic production process using the Lean six sigma (LSS) method and Failure Mode Effect and Analysis (FMEA) as proposed recommendations for improvement. Lean six sigma uses 5 stages, namely define, measure, analyze, improve, control. However, research is carried out to the improvement stage to provide recommendations for improvement. The results of reducing the lead time value in the ceramic production process, which was originally 1880 minutes, changed to 1816 minutes or decreased by 64 minutes, thereby reducing the cycle time in the ceramic production process. Then the DPMO value obtained was13311 with a sigma level of 3.71. The research results show that crack defects have the highest RPN value of 576 with the cause being that the punches on the press machine have reached their useful life, causing the printing process to be less than perfect. The proposed recommendation for improvement is replacing the punches components on the press machine

Analisis Pengendalian Kualitas untuk Mengurangi Cacat Produk 3D VR (Virtual Reality) Garment dengan Menggunakan Metode Six Sigma

Pan Brothers Tbk is one of the garment companies that adopted garment production in the form of 3D VR (Virtual Reality) as a garment prototype in Indonesia. In the process of making 3D VR products, many defective products must be revised. The study aims to implement the Six Sigma method and suggest improvements to reduce defects in 3D VR garment products using the Six Sigma method with the stages of defining, measuring, analyzing, improving, and controlling. In the define stage, the identification of the production process using the SIPOC diagram and identifying the type of defect. In the measure stage, the DPMO and sigma value calculations are carried out. The most defects are fitting not balanced and properly with a DPMO value of 269619.2 and a sigma value of 2.11. In the analysis stage with a fishbone diagram shows the factors that cause defects, namely man, machine, material, method, and environment. In the improvement stage, suggestions for improvements are given to reduce defects in 3D VR garment products. In the control stage, quality control is carried out by conducting internal training, upskilling, creating inspection report forms, adding teams to the QC division, and adding SOPs for the 3D VR producing process.

Analysis Of Improving Service Quality At The Ssctelkom Surabaya Institute Of Technology Using The Lean Six Sigma Method

Student Service Centre (SSC) is a center that provides services and information to active students at InstitutTeknologi Telkom Surabaya (ITTS). ITTS provides SSC with academic, student, and faculty services to support its students' academic and non-academic development. One of the main services provided by SSC is the Active Certificate. However, SSC users need help obtaining the letter. This study aims to measure the quality of Active Certificate services using the Lean Six Sigma method and provide recommendations for improvement. The results showed that the quality of SSC services still needs to be improved, with a DPMO value of 289686, a sigma value of 2.07, and the highest negative gap in the Responsiveness dimension. The total Non Value Added time was obtained at 10 hours 31 minutes, and the total Value Added time was 4 hours 8 minutes. Proposed improvements include the deployment of QR Codes to provide information on document requirements and using Value Stream Mapping (VSM) to reduce the time spent on non-value added. Lean Six Sigma method can reduce the total value-added time and improve the efficiency of SSC services.

Quality Control of Ceramic Wall Products Six Sigma Method with Dmaic Tools and Failure Mode and Effect Analysis (FMEA)

Considering the importance of increasingly rapid industrial development, business people must be aware of the orientation towards product quality. The manufacturing industry has an important role in industrial development. It is hoped that it will be able to grow and have advantages in industrial development, therefore it is necessary to improve and increase product quality. The company continues to strive to maintain and improve product quality and increase productivity so that customers are satisfied with the products produced. One way that needs to be done is to reduce the number of defective products in the production process. This effort is one way of continuous improvement carried out by PT. ABC and companies operating in the same field. The ceramic wall production process has relatively high demand but still has a high level of defects. Based on information on production data and data on the number of defects for the period January – September 2023, wall ceramic production has a defect rate of 3.86%. Companies must reduce the number of defects to achieve company targets. This research aims to improve the production process of wall ceramics by minimizing the number of defective products. This research uses the six sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) tool assisted by the FMEA (Failure Mode and Analysis) method. Corrective action to reduce defects based on the 5 Why analysis is to find out what the problem is and ask "why" and "what is the root of the problem". The research results show that there are 4 types of defects which have a large number of defects, namely Rupture Defects, Application Defects, Peeling Defects and Hole Defects. From the research results, solutions were obtained for the emergence of several types of defects in the wall ceramic production process, namely by providing planning suggestions and corrective actions which are discussed this time. At the defect calculation stage, Broken produces a DPMO value of 29.362 with a sigma level of 3.39 with a sigma level of 3.48, Defect Peeled produces a DPMO value of 28.044 with a sigma level of 3.38, and holes are defective. resulting in a DPMO value of 26,020 with a sigma value of 3.45 from the data calculation results, it is still not enough to meet the company's target at the sigma level, therefore the company must make quality improvements to achieve the main target at the sigma level.

Analisis Pengendalian Kualitas Produk Teh Hitam dengan Pendekatan Lean-Six Sigma Method di PT. Teh XY

PT. XY tea is a black tea processing company, the problem faced is the presence of tea powder that has a production defect that must be reworked because the water content does not meet the standard (3-4%). The purpose of this study was to analyze the quality control of black tea products by identifying the relationship between the types of waste at the work station and measuring the sigma level value. The method used to identify the interrelationships between wastes is by using the Waste Relationship Matrix and making a control chart graph and then calculating the DPMO value and Sigma Level to measure the level of production capability. The results showed that the largest percentage level for waste that has an influence on other types of waste is waste of motion (22.50%) at the sorting stage, the waste that is often affected is inventory (19.63%) at the milling stage. For the production of quality I black tea, the sigma value is 2.31 with a DPMO value of 210605, meaning that for every one million opportunity there is a possibility of 210605 units of rework products. Meanwhile, for quality III, the sigma value is 2.55 with a DPMO value of 150661.

Reducing Defects Using DMAIC Methodology in an Automotive Industry

Quality is when it meets the wants and expectations of customers or even exceeds them. Every company must raise the quality of its current products and services. A complete and adaptable approach for establishing, maintaining, and maximizing company success is Six Sigma. Define, Measure, Analyze, Improve, and Control (DMAIC) is one of the tools used to implement Six Sigma. PT. KRM is one company engaged in the automotive sector, which produces Colt Diesel trucks. This research focuses on the welding processes. Defective products were found in as much as 5% of total production, exceeding the company's target of 3%. This research was conducted to determine the process capability based on product defects with the Six Sigma DMAIC method approach, then to find out the proposal for implementing quality control by analyzing the causes of defects in the production process and then looking for continuous improvement with the 5W+1H concept. The improvement was made to decrease the DPMO value of 4.496 and increase the sigma value of 0.19. This study demonstrates how the Six Sigma DMAIC approach can improve the quality of the cabin production process for the part side outer pillar LH. This case can help company managers apply Six Sigma methods to solve complex problems in other processes.

Analysis of Improving the Quality of Fatty Acid Methyl Ester (FAME) Products Against Acid Value (AV) Levels Using the Six Sigma and Kaizen Methods

. PT XYZ is a palm oil derivative processing company that produces biodiesel / FAME (Fatty Acid Methyl Ester) products. However, there are several obstacles that still occur during the company's production process which causes the acid value (AV) level of FAME products to not meet specifications and there are 3% defective products. Therefore, this study aims to determine the improvement plan by applying kaizen to the Six Sigma improvement stage and reducing outspec products in the FAME production process. The results of the research conducted using the six sigma method show that the company has a DPMO value of 71,459 and a sigma value of 2.96 which is in the average position of the industry in Indonesia based on the results of data processing. While recommendations for improvement by implementing kaizen include training machine operators, making standard operating procedures (SOPs) for machine inspections on each shift, reducing the amount of strearin added to AV raw materials before pre-treatment, maintenance and machine calibration. This step are expected to overcome the main problems identified in the study.

Implementasi Metode Six Sigma dengan Pendekatan DMAIC untuk Meminimalisasi Kecacatan Produk Pancong Pocong UMKM Ketintang

SME’s Pancong Pocong Ketintang, an SME’s in Surabaya, is currently facing problems with its products and packaging. Packaging is often not tight and breaks easily, causing the topping to overflow and the packaging to become dirty. To reduce packaging defects, the Six Sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) approach is used. This method is effective in reducing defects and improving quality. The result of this research is that the researcher defines the types of defects that exist and determines critical to quality. In the measurement stage, the average DPMO value is 157,088, which means it has a sigma level of 2.51. At the analyze stage, the results obtained from the Pareto diagram showed that the most dominant type of defect was overflowing packaging, amounting to 48%. In the improvement stage, improvements are made using the kaizen five m checklist tool which consists of man, material, method and environment. The final stage, the improvement control provided can be implemented on an ongoing basis by implementing operational standards.

Quality Improvement of Floor Cleaner Packaging Using Six Sigma and Continuous Improvement

There was a product defect in the 700 ML Lemongrass Refill Floor Cleaner packaging, which was 26,236 units from June to December 2021. The cost overrun was Rp. 15,085,700. This study aimed to improve the quality of the 700 ML Lemongrass Floor Cleaner packaging. The research method used was quantitative, and examined the quality of product packaging with Six Sigma and Continuous Improvement methods. The results of research conducted for the DPMO value before any improvement was 65,121 with a sigma level of 4.51. Then improvements were made so that the DPMO value became 12,517 with a sigma level of 5.26, resulting in a decrease in waste in the production process. So it can be concluded that we can provide solutions by replacing spare parts that are no longer suitable for use, making sure the machine is set correctly, making the standard materials used without defects and maintaining their shape, arranging the pouch arrangement as neatly and efficiently as possible, checking the pouch at the supplier, adjusting the machine settings, making sure it is neatly organized and performing regular machine maintenance according to the SOP.
 Keywords: continuous improvement, floor cleaner packaging, six sigma, quality

The Application of Six Sigma Framework (Define-Measure-Analyse-Improve-Control) to Improve Product Quality in Water Dispenser Manufacturing Company

This research aims to determine the causes of water dispenser product defects and find the main factors causing defects. This research was conducted in the form of a case study. The data used consists of quantitative data, supported by qualitative data. The analytical method used is Six Sigma, with a focus on the DMAIC method (define, measure, analyze, improve, and control) and sigma values. The population of this research is all water dispenser product equipment. Through observation, interviews and documentation techniques, this research collected data. The data processing method used is DMAIC Six Sigma, with a special focus on the Measure stage. Based on the research results, it was found that the process performance of the water dispenser product was at the level of 4.72 sigma with a DPMO value of 633,732. The most dominant defect occurs in the motor pump. Causes of defects in water dispenser products include human factors (inexperienced operators, errors in reading work instructions, unclear job holders, products not completed on time), materials (parts that do not meet standards, inspection/test equipment that does not function, CBU units that do not conform to standards), methods (products do not meet customer expectations, finished products do not meet standards, inspector operators do not master the use of measuring equipment according to regulations, customer complaints are not handled properly), and environment (hot room conditions, unstable room temperature). The most influential cause and priority for improvement is that customer complaints are not resolved or solutions are sought by the supplier.

Analisis Pengendalian Kualitas Produk Intimates Bra Fused untuk Meminimalkan Defect dengan Menggunakan Metode Six Sigma

PT. Diamondfit Garment Indonesia is a company operating in the apparel industry, especially intimates and swimware. One of the products is the Intimates fused bra. In the production process, many defects are still found. This research aims to propose quality improvements using the six sigma method starting from the define, measure, analyze, improve and control stages. At the define stage, the production process is identified using the SIPOC diagram and identification of the type of defect. At the Measure stage, the calculation stage is carried out: fusing delamination DPMO value 366405.6 with a sigma value 1.84, Wavy At Neckline & Armhole DPMO value 65274.15 with a sigma value 3.01, Molding Yellowish DPMO value 350739.8 with a sigma value 1, 88, Dirty Glue has a DPMO value of 26109.66 with a sigma value of 3.44, and Heat Seal Not Sticking has a DPMO value of 191470.8 with a sigma value of 2.37. As a result of the analysis, it was found that factors causing defects occurred using FMEA tools and fishbone diagrams, namely machine, manpower, material and method factors. In the improvement stage, improvements are made to the factors causing defects and in the control stage, supervision is carried out over the proposed improvements that have been made by creating SOPs.

Product Quality Improvement of Stainless Steel Round Trash Can with Six Sigma Approach and Fuzzy Analytical Hierarchy process Method at PT. XYZ

PT. XYZ is a manufacturing industry that produces various cleaning equipment. One of the products that has a high level of defects are trash bins made of stainless steel. The purpose of this research is to improve the quality of stainless steel waste products. The method used is Six Sigma and Fuzzy Analytical Hierarchy Process. In the Define stage, the types of defects found were body dents, scratches, spots, and rough covers. In the Measure stage, the initial DPMO value obtained is 3.422. In the Analyze stage, the results of the analysis process are defects with the highest Risk Priority Number of 280. The next stage is Improve, where defects with the highest RPN value are prioritized for proposed improvements using Fuzzy AHP. Based on the results of the Fuzzy AHP assessment, it was found that the highest weight was alternative 3, namely the machine must be cleaned regularly after being used at 0.4322, alternative 2, namely the addition of material handling to facilitate product transfer of 0.2048, and alternative 4, namely the establishment of SOPs for product handling. of 0.2041. After the Improve stage, the final stage in the form of Control is carried out to see whether the implementation of the proposed improvements has a positive impact on the company. The DPMO results obtained after implementation were 3.6061.

Reducing Wall Shelf Product Defects Using the DMAIC Method in Furniture Industry Companies

The object of research is a place of business that produces household needs and wood-based industries. One of the products it produces is a minimalist wall shelf. In the period January –December 2021 minimalist wall shelf products are the products with the most defects. Manufacturing companies in this study have a product defect tolerance limit of 5% of the total production, but minimalist wall shelf products have a defect of 5.64%. This study aims to determine the types of defects that occur in wall shelf products, identify the causes of defects minimalist wall shelves and provide suggestions for improvements to reduce the number of future defects. In this research the method used is DMAIC. In the minimalist wall shelf production process, 4 types of defects were found. Based on the Pareto diagram, it was determined that the type of lacquer defect was not suitable to be the most dominant type of defect, namely 80.1%, it was also found that the DPMO value and sigma value on minimalist wall shelves were 14,100 and 3.69. Based on the analysis of the fishbone diagram method and Failure Mode and Effect Analysis (FMEA), it is known that the main root cause of product defects is a dirty, dusty and windy environment with an RPN (Risk Priority Number) value of 448. Analysis was carried out using the 5W + 1H approach to find improvements to overcome the problems that occur, obtained suggestions for improvements for the company, namely making work area picket schedules, making closed work areas, daily and monthly check sheetforms for maintenance of work tools, making varnish process work instructions, making training schedules for operators and submitting additional goods forms.

The Use of the DPMO Indicator to Verify the Fulfilment of Hygienic Requirements in the Food Industry - A Case Study

Abstract The quality of the manufactured product plays a special role in the food industry. Food producers, in addition to meeting consumer requirements, are obliged to comply with legally sanctioned, rigorous requirements of hygiene and cleanliness at work, as well as the way it is performed. In order to maintain the legally required hygiene rules in production plants specializing in the production of food products, manufacturers implement numerous management systems aimed at maintaining legally imposed guidelines in the field of quality management and occupational health. The article describes the use of the DPMO indicator, which allows for a thorough analysis of process parameters affecting the final quality of the manufactured product. For the analyzed process, the maximum DPMO value for one of the areas is 636364. In nine cases, which constitutes 12.5% of the total, DPMO is 0. The purpose of this article is to identify non-compliances in the field of occupational hygiene in the production plant analyzed using the DPMO indicator and then to introduce improvements. The developed recommendations concern marking, standardization and responsibility for individual processes as well as additional cleanliness inspections.

Improving Quality of Wedding Event Management to Reduce Common Mistakes at Mahar Agung Organizer Using the Six Sigma Method

This research aims to improve the quality of wedding event management at Mahar Agung Organizer using Six Sigma and DMAIC. The data used in this research is data on the number of events managed by Mahar Agung from 2021 to 2023. At the define stage, it was found that the type of defect that most often occurred at wedding events was events that did not run according to the rundown. At the measure stage, the DPMO value was obtained at 103,552 with a sigma value of 2.762. From the results of the analysis using a cause-and-effect diagram, it was found that several main factors caused defects in wedding event operations, including additional events outside the runway, delays in the arrival of vendors or guests, poor communication and crowded guests. In the improve stage, improvements were made to the process to obtain a DPMO value of 23,809 and a sigma value of 3.481, where there was an increase in the sigma value of 0.719. Improvements in service quality are carried out by providing training to official crew, details in event guidebooks, as well as improving communication methods so that the number of errors or defects can continue to decrease

Analysis of the Factors Causing Delays of Delivery Using the Six Sigma Method (Case Study: Kompindo Wiratama Inc.)

The distribution of goods is a very important part of the service or manufacturing industry. One way to maximize the product distribution process is to maintain the quality of service. Service quality is how a company meets or exceeds customer expectations. The problem experienced by Kompindo Wiratama Inc. occurs because of production target discrepancies resulting in delays due several factors. One method that can be used for reducing delivery delays to improve service quality, namely the method of Six Sigma using DMAIC. The concept of DMAIC starts from a stage that define, measure, analyze, improve, and control and at each stage, D-M-A-I-C has objectives and tools different. Obtained an average DPMO value of 33349.08 and an average sigma value of 3.3691. The sigma level that has been achieved is still far from the Decried target, namely 3.4 DPMO and 6 Sigma. The repair phase uses the 5W + 1H analysis technique based on the source of the problem at the fishbone diagram of each CTQ to explain the proposed results of the analysis. After the results of the proposal are given based on the method Six Sigma improvements in handling the four factors of delivery delays will reduce the occurrence of delivery delays in the following months and years. This can improve the quality of service in delivery and maintain customer trust by the company motto, which is "delivery, quality and zero defect”.

Pengendalian Kualitas Produk Menggunakan Lean Six Sigma dan Fuzzy FMEA Dalam Upaya Menekan Kecacatan Produk

Quality control is a process used to ensure the level of quality in a product or service so as to lead to customer satisfaction. UMKM Eko bubut is a UMKM that produces wooden handicrafts with product marketing that reaches the international market. In the problem of product quality control at UMKM Eko Bubut, it was found that there were five types of defects, namely wavy, rough, perforated, cracked, and broken defects. In addition, it was found that there was wastage that occurred which had an effect on disability. Solving quality control problems at UMKM Eko Bubut is by using lean six sigma to identify the sigma level and fuzzy FMEA is used to determine the main priority for repairs to the causes of production defects that occur. The results of the calculation of the defect level of bowl products, it was found that the types of defects were wavy (55.06%), rough (28.29%), perforated (7.82%), cracked (7.22%) and broken (1.61%). The identification results of the waste that occurs are waste defects (28.1%), waste overproduction (17.7%), waste waiting (16.2%), waste motion (16.0%), waste inventory (10.75%), waste transportation (6.55%), and over-processing (4.9%). The results of calculating the DPMO value obtained an average sigma of 3.27 with a DPMO value of 38890.41. This shows that for every 1,000,000 production, there is a possibility that there will be product defects in as many as 38,890 products. Factors that affect product defects are humans, raw materials, methods, machines, and the environment.

Enhancing Automotive Part Quality in SMEs through DMAIC Implementation: A Case Study in Indonesian Automotive Manufacturing

Purpose: The purpose of this study is to reduce defects and improve the quality of automotive parts at SMEs by implementing the define, measure, analyze, improve, and control (DMAIC) stage of Six Sigma.
 Methodology/Approach: The application of the DMAIC method was carried out in an automotive component manufacturing company in Indonesia that produces Stay B Muffler Protector HC21 as a research object. The cause of the high number of product defects is known at the define stage. In the measure stage, details from field data are collected and sigma levels are determined.
 Findings: The results of the improvement actions taken have an impact on the DPMO value and an increase in the sigma level. DPMO value decreased by 19,891 from 22,230 to 2,339. Meanwhile, the sigma level increased by 0.82 from 3.51 to 4.33. To control the sigma level, it is proposed that improvement be carried out by making work instructions for the use of spot welding tools so that it can be standardized, controlled continuously, and make continuous improvements.
 Research Limitation/implication: Limitations of this study may include limitations in covering all aspects of production or other factors that may affect product quality.
 Originality/Value of paper: The originality of this paper lies in the application of the DMAIC method of Six Sigma in the context of automotive manufacturing SMEs in Indonesia.

WASTE REDUCTION IN BRAKE LINING PRODUCTS TYPE 51 HS USING LEAN SIX SIGMA METHOD

Every company desires a profit, and its production system must continually develop and become more productive. Companies can boost their production productivity in a variety of ways, including by enhancing their production process system and removing impediments. This research was conducted at a company in Tangerang that specialized in manufacturing brake linings. On the basis of the results of field research, manufacturing department defects and inventory have been detected. The research phases employ the DMAIC model. The define phase employs SIPOC and CTQ diagrams. Using WAM to identify waste that happens through the distribution of questionnaires during the measurement phase. According to the measure stage's calculation, the company's current efficiency level is 26.85 percent. The DPMO value is 6,222.71 and sigma number indicates a quality level of 4.91. After learning the company's status, the research continued with an FMEA examination of the root cause. On the basis of the results of the analysis, proposals for changes to the brake linings production steps were made. The research was continued in the third phase, known as control, which consisted of recalculating the company's status after the implementation of modifications. The calculation findings demonstrate an increase in process cycle efficiency to 35.33 percent. In addition, a reduction in the value of faults per million opportunities resulted in the production of 4,524.88 products and an increase in the sigma level to 5.12. This demonstrates a gain in efficiency of 8.48%, a drop-in DPMO of 1,697.83 products, and a 0.21 increase in sigma value.

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%.