Implementation of DMAIC Six Sigma for Product Defect Analysis and Improvement Strategy

Adinda Nurlaela; Muchammad Fauzi

doi:10.24014/jti.v11i1.35323

Implementation of DMAIC Six Sigma for Product Defect Analysis and Improvement Strategy

Adinda Nurlaela, Muchammad Fauzi

Abstract

This study focuses on a micro, small, and medium enterprise (MSME) operating in the rattan handicraft industry, which specializes in the production of home decor items such as plant stands. During the production of 9,000 Base Plant Stand units, the company recorded 2,305 defective products, resulting in a sigma level of 3.14. This study aims to identify the root causes of product defects and propose effective process improvement strategies using a combination of qualitative and quantitative approaches. The research employed the DMAIC (Define, Measure, Analyze, Improve, Control) methodology of Six Sigma to analyze production data and determine key defect categories. The dominant defects identified were mold (27.9%), imprecision (22.7%), and loose ties (20.9%). Root causes included high humidity levels, suboptimal oven performance, limited workspace, and insufficient operator skills. Based on direct observations and literature studies, proposed improvements include covering products during rain, measuring and managing moisture content, conducting routine oven maintenance, expanding WIP (Work-in-Process) areas to prevent excessive stacking, and developing clear, detailed SOPs. These actions aim to enhance production quality and raise the company’s sigma level through continuous improvement. This study serves as a reference for optimizing defect reduction efforts in MSME-scale rattan production.

Keywords: Six Sigma, DMAIC, Quality Control, Product Defect, Rattan Handicrafts

Full Text:

PDF

References

M. L.Teklehaimanot, “Customer–Centric informal business marketing in Africa: the case of Ethiopian MSMEs ,” Small Enterp. Res., vol. 30, no. 2, pp. 154–170, 2023, doi: 10.1080/13215906.2022.2086610.

M.Singh, “Analysis and prioritization of Lean Six Sigma enablers with environmental facets using best worst method: A case of Indian MSMEs,” J. Clean. Prod., vol. 279, 2021, doi: 10.1016/j.jclepro.2020.123592.

F.Ahmad, “Six Sigma Dmaic Sebagai Metode Pengendalian Kualitas Produk Kursi Pada Ukm,” Jisi Um, vol. 6, no. 1, p. 7, 2019.

F.Choirunnisa andT.Nova, “Implementasi Lean Six Sigma dalam Upaya Mengurangi Produk Cacat pada Bagian New Nabire Chair Kursi Rotan,” EDUSAINTEK, vol. 4, 2020.

L. I. K.Nafiah andL.Herdiman, “Penerapan Six Sigma sebagai Metode Pengendalian dan Perbaikan Kualitas Produk Kursi Rotan,” in Seminar Dan Konferensi Nasional IDEC 2023, 2023, pp. 1–9.

R. C.Lestari, K. F.Handayani, G. G.Firmansah, andM.Fauzi, “Upaya Meminimalisasi Cacat Produk Dengan Implementasi Metode Lean Six Sigmas: Studi Kasus Perusahaan PT XYZ,” J. Bayesian J. Ilm. Stat. dan Ekon., vol. 2, no. 1, pp. 82–92, 2022.

V.Gaspersz, “Total Quality Management, PT,” Gramedia Pustaka Utama, Jakarta, 2001.

M.Yusuf andE.Supriyadi, “Minimasi Penurunan Defect Pada Produk Meble Berbasis Prolypropylene Untuk Meningkatkan Kualitas Study Kasus: PT. Polymindo Permata,” Ekobisman J. Ekon. Bisnis Manaj., vol. 4, no. 3, pp. 244–255, 2020.

A. F.Sanny, M.Mustafid, andA.Hoyyi, “Implementasi metode lean six sigma sebagai upaya meminimalisasi cacat produk kemasan cup air mineral 240 ml (studi kasus perusahaan air minum),” J. Gaussian, vol. 4, no. 2, pp. 227–236, 2015.

L. L.Salomon, A.Ahmad, andN. D.Limanjaya, “Strategi Peningkatan Mutu Part Bening Menggunakan Pendekatan Metode Six Sigma (Studi Kasus: Department Injection Di PT. KG),” J. Ilm. Tek. Ind, vol. 3, no. 3, pp. 156–165, 2017.

R.Oktaviani, H.Rachman, M. R.Zulfikar, andM.Fauzi, “Pengendalian Kualitas Produk Sachet Minuman Serbuk Menggunakan Metode Six Sigma Dmaic,” J. Ilm. Tek. Dan Manaj. Ind., vol. 2, no. 1, pp. 122–130, 2022.

D.Caesaron andT.Tandianto, “Penerapan Metode Six Sigma Dengan Pendekatan DMAIC Pada Proses Handling Painted Body BMW X3 (Studi Kasus: PT. Tjahja Sakti Motor),” Penelit. dan Apl. Sist. dan Tek. Ind., vol. 9, no. 3, p. 182846, 2015.

I.Doyer, “As easy as OEE: enabling productivity improvement in schools by using overall equipment effectiveness as framework for classroom data analysis,” Int. J. Lean Six Sigma, vol. 14, no. 5, pp. 1055–1074, 2023, doi: 10.1108/IJLSS-03-2022-0057.

A.Scala, “Lean six sigma approach for reducing length of hospital stay for patients with femur fracture in a university hospital,” Int. J. Environ. Res. Public Health, vol. 18, no. 6, pp. 1–13, 2021, doi: 10.3390/ijerph18062843.

V.Swarnakar, “Evaluating critical failure factors for implementing sustainable lean six sigma framework in manufacturing organization: A case experience,” Int. J. Lean Six Sigma, vol. 11, no. 6, pp. 1083–1118, 2020, doi: 10.1108/IJLSS-05-2019-0050.

A.Chiarini, “Lean Six Sigma and Industry 4.0 integration for Operational Excellence: evidence from Italian manufacturing companies,” Prod. Plan. Control, vol. 32, no. 13, pp. 1084–1101, 2021, doi: 10.1080/09537287.2020.1784485.

D.Shah, “Customer-centric marketing: what, how, and why do customer habits matter?,” Handbook on Customer Centricity: Strategies for Building a Customer-Centric Organization. pp. 157–179, 2019. doi: 10.4337/9781788113601.00014.

I.Gabelaia, “The Enrollment Marketing Playbook: Employing Enrollment Marketing Strategies into Student-Centric, Customer Service-Oriented Recruiting Environment,” Lecture Notes in Networks and Systems, vol. 195. pp. 782–792, 2021. doi: 10.1007/978-3-030-68476-1_72.

R. P.Adi andH.Supriyanto, “Penerapan Metode DMAI dan FMEA untuk Peningkatan Kualitas Cement Retarder Gypsum Granulated di Unit III Pabrik Cement Retarder PT,” Petrokimia Gresik. Inst. Teknol. Sepuluh Novemb. Surabaya, 2011.

H.Tannady andC.Chandra, “Analisis pengendalian kualitas dan usulan perbaikan pada proses edging di pt rackindo setara perkasa dengan metode six sigma,” JIEMS (Journal Ind. Eng. Manag. Syst., vol. 9, no. 2, 2017.

M.Rachmawati andJ.Purnama, “Analisis Pengendalian Kualitas Guna Meminimalkan Jumlah Cacat Pada Produk Nice Burlwood Console Table,” Ind. Inov. J. Tek. Ind., vol. 14, no. 1, pp. 116–123, 2024.

A.Wicaksono andF.Yuamita, “Pengendalian Kualitas Produksi Sarden Mengunakan Metode Failure Mode and Effect Analysis (FMEA) Untuk Meminimumkan Cacat Kaleng Di PT. Maya Food Industries,” J. Teknol. dan Manaj. Ind. Terap., vol. 1, pp. 1–6, 2022, doi: https://doi.org/10.55826/tmit.v1iI.6.

A. M.Ponsiglione, “A six sigma DMAIC methodology as a support tool for health technology assessment of two antibiotics,” Math. Biosci. Eng., vol. 18, no. 4, pp. 3469–3490, 2021, doi: 10.3934/MBE.2021174.

R. C.Pratiwi, C.Iswayudi, andR. Y.Rachmawati, “Sistem Manajemen Persediaan Barang Dagang Menggunakan Metode Safety Stock dan Reorder Point Berbasis Web (Studi Kasus: Art Kea Centro Plaza …,” J. Scr., vol. 7, no. 2, pp. 213–222, 2019.

J. R.Evans andW. M.Lindsay, An introduction to Six Sigma and process improvement. Cengage Learning, 2014.

D.Didiharyono, M.Marsal, andB.Bakhtiar, “Analisis pengendalian kualitas produksi dengan metode six-sigma pada industri air minum PT Asera Tirta Posidonia, Kota Palopo,” Sainsmat J. Ilm. Ilmu Pengetah. Alam, vol. 7, no. 2, pp. 163–176, 2018.

I. A.Jasmine, S. A.Salma, andH.Susanto, “Jersey Production Quality Control Using Six Sigma and FMEA Methods To Minimize Product Defects,” J. Tek. Ind. J. Has. Penelit. dan Karya Ilm. dalam Bid. Tek. Ind., vol. 10, no. 2, pp. 413–423, 2024.

DOI: http://dx.doi.org/10.24014/jti.v11i1.35323