QUALITY IMPROVEMENT IN THE FILO BOTTLE PRODUCTION PROCESS USING THE SIX SIGMA METHOD AT PT. CAHAYA PERDANA PLASTIK
Abstract
This study aims to analyze and identify the dominant causes of failure in the filo bottle production process at PT. Cahaya Perdana Plastik and to propose improvements to reduce the number of defective products. The method used in this study is Six Sigma with the DMAI (Define, Measure, Analyze, and Improve) stages. The data used is defective product data from October 1 to November 31, 2020, in the Injection section. The analytical tools used include P-Charts, Pareto Charts, Cause and Effect Diagrams (Fishbone), and FMEA (Failure Mode and Effect Analysis). The results show that out of a total production of 73,552 filo bottles, 6,819 were defective. The most dominant type of defect is color not according to standard as many as 3,720 units, followed by thin defects as many as 2,204 units, silvermark as many as 515 units, and bubbles as many as 380 units. Based on the measurement results, the DPMO value was obtained at 425,460.64 with a sigma level of 5.41. The results of the Cause and Effect Diagram analysis showed that human factors were one of the main causes of color defects not according to standard, especially operators who paid less attention to the condition of mova and were less careful in adjusting the mova dye. The FMEA results showed the highest RPN value of 294 in the human aspect. The proposed improvements included increasing operator accuracy and discipline in operating mova, checking the condition of mova periodically, and ensuring that mova settings were in accordance with standards before and during the production process. By implementing these proposed improvements, it is expected that the number of defective products, especially color defects not according to standard, can be minimized and the quality of the bottle filo production process can be improved.
Keywords
Monthly Statistics (Last 12 Months)
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