The global market demand for automotive wheels with alloy materials is 55%, which is quite high compared to other materials such as steel, magnesium, chromed, and carbon fiber. The high competition of the global alloy wheels market demands to be able to offer quality alloy wheels. The purpose of this research is to reduce the number of defects in the casting process step by using the Define Measure Analyze Improve Control (DMAIC) method. This study shows the systematic approach to find the root cause of major defects in aluminum castings using the defect diagnostic approach as well as cause and effect diagram. Quality improvement using quality tools, namely the Pareto diagram, fishbone diagram. The major defects for the rejections during production were identified as leak defects, porosity motive holes, and oval defects. In determining the proposed quality improvements using the FMEA tool. The results of data processing on the calculation of process capabilities and product performance show improvements after quality improvements in the casting process. Product performance from DPMO = 15.462, sigma level = 3.6 to DPMO = 8.186 and sigma level = 3.9. The effect of decreasing the percentage of defects could save production costs by IDR 413.350.000. Therefore, the application of the DMAIC method can provide a significant improvement in product quality and impact on production cost savings.

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