Quality Control Analysis of Plastic Product Utilizing Six Sigma with DMAIC Stage: A Case Study

DOI

10.2991/978-94-6463-566-9_18How to use a DOI?

Keywords

Six Sigma; DMAIC; Trash Bag; FMEA; Kaizen

Abstract

Sigma method with DMAIC is a systematic improvement step to achieve the desired results, which is a flexible and comprehensive system for achieving and maintaining success in business. In this study, this method was implemented to analyze the quality control of trash bag produced by one of the plastic industries. Based on the initial research survey, trash bag in the production period from November 2023 to January 2024 had a defect rate of 5.28%, which did not meet standard, i.e. 5%. This research aims to analyze quality control during the trash bag production process in order to minimize the number of defects production. The Six Sigma DMAIC stage was chosen as a quality control method to analyze defect type, DPMO, sigma level, process capability, and provide some recommendations to improve the production process. The use of the Six Sigma DMAIC stage was combined with Failure Mode and Effect Analysis (FMEA) to determine the failure mode which made the biggest contribution of defects. In addition, Kaizen 5W + 1H improvement concept was used to obtain recommendations for minimizing the number of defects. Results showed recommendations for improvement were provided in the form of Standard Operating Procedures (SOP) for machine operation and machine failure check sheets. The SOPs and check sheet was implemented for four days, resulted in a 26% reduction in DPMO. This reduction in DPMO aligned with the increase in sigma level from 3.538 sigma to 3.776 sigma.

Copyright

© 2024 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Rani Puspa Abadi
AU  - Aprilia Riyanto
AU  - Kartika Nur ‘Anisa’
AU  - Gunawan Setia Prihandana
PY  - 2024
DA  - 2024/11/01
TI  - Quality Control Analysis of Plastic Product Utilizing Six Sigma with DMAIC Stage: A Case Study
BT  - Proceedings of the  International Conference on Advanced Technology and Multidiscipline (ICATAM 2024)
PB  - Atlantis Press
SP  - 277
EP  - 292
SN  - 2352-5401
UR  - https://doi.org/10.2991/978-94-6463-566-9_18
DO  - 10.2991/978-94-6463-566-9_18
ID  - Abadi2024
ER  -