Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Setiawan, Indra; Setiawan, Setiawan

doi:10.30656/jsmi.v4i2.2775

Cited by 16 publications

(11 citation statements)

References 20 publications

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“…The relationship among the SIPOC elements and the key area of conflict that create the problem are possibly revealed in this analysis. An example of SIPOC analysis is given in Setiawan and Setiawan [15].…”

Section: Methodsmentioning

confidence: 99%

Application of lean six sigma methodology to improve the weight inconsistency problem of coffee powder packaging

Aziz¹,

Ahmad²,

Mustafa³

et al. 2021

j. sist. manaj. ind.

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This paper presents a continuous improvement (CI) project based on the application of Lean Six Sigma (LSS) methodology. This project was carried out at coffee manufacturing industry located in northern area of Malaysia. The focus of this presented CI project is to improve the weight inconsistency problem of coffee powder packaging. The presented CI project was mainly guided with Six Sigma methodology of Define, Measure, Analyze, Improve and Control (DMAIC) steps, and related Lean tools applications. The step of Define summaries the overall view of CI project. In the step of Measure, current level of sigma based on defect per million of opportunities (DPMO) calculation was determined. Initially, 6% of rejected products were recorded, which it presents the sigma level at 3.1. In the step of Analyze, a series of team-based activities towards root cause identification was carried out. It included the applications of cause effect (CE) analysis and possible causes prioritization and close observations on packaging process. In the step of Improve, the related Lean tool was proposed to improve the problem under study. In the final step of Control, related supportive actions were suggested to sustain the effectiveness of the proposed solution. There are fourteen possible causes are initially identified in CE analysis and based on team’s evaluation process of possible causes prioritization four causes are collectively to be the most possible of root cause(s). Three close observation sessions were carried out to finalize the most possible root cause of the problem. Result strongly suggested that the high variation of coffee powder’s size and inconsistency is the root cause. An improvement strategy based on Lean Manufacturing approach called ‘poka yoke’ is proposed. The proposed improvement strategy was then validated based on real packaging process scenario. Result shows that the proposed improvement strategy is significantly effective to solve the problem with 0% of reject product was recorded so far, where it is not only produced the product within the acceptable weight of 215 and 208 grams, but also presents the reduction of weight fluctuation that close to ideal weight of 208 grams.

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Section: Methodsmentioning

confidence: 99%

Application of lean six sigma methodology to improve the weight inconsistency problem of coffee powder packaging

Aziz¹,

Ahmad²,

Mustafa³

et al. 2021

j. sist. manaj. ind.

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show abstract

“…In contrast, the quantity of faulty products positively affects production costs (Sihombing & Sumartini, 2017). The DMAIC phase effectively controls and improves product quality levels in the automotive industry (Setiawan & Setiawan, 2020).…”

Section: Introductionmentioning

confidence: 99%

Implementation of the Dmaic Approach for Quality Improvement at the Elastic Tape Industry

2022

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The scope of this research is in one of the textile industries with elastic tape produced on the weaving machine, which has decreased production due to production defects that do not meet the target. This research aims to determine the leading causes of dominant defects, increase the sigma level with Six Sigma methods, and propose improvements to be included in the Key Performance Indicators (KPI) method. The results of this study that the dominant factor causing the defect is the curved elastic tape defect, which consists of the machine factor, and the method. Factors driving the machine include the hook like a side thread lock that is often bent and the difference in the thickness of the tape between the left, middle and right. The causative factor of this method is checking the thickness of the elastic band only in the center position. The results of corrective actions impact increasing the sigma level by 10% from 3.3339 to 3.6832. In contrast, repair defects can reduce defects before repair by 18.92% and after repair by 9.23%. It is proposed to be included in the KPI so that the weaving department can control and be enthusiastic about continuous improvement.

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“…VSM can assist companies in identifying non-value added activities (Kosasih et al, 2019). Meanwhile, Six Sigma is an improvement to reduce variance in products so that they can provide value to customers (Belu et al, 2018;Setiawan & Setiawan, 2020). The popular Six Sigma method used is DMAIC (Bhargava & Gaur, 2021).…”

Section: Introductionmentioning

confidence: 99%

Enhance quality improvement through lean six sigma in division Side Board Clavinova Piano’s

Hernadewita

Setiawan

Hendra

2022

Int. J. Prod. Manag. Eng.

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A lean production system is one of the main factors that every company must have to improve quality, especially reducing waste that occurs in the production line. The musical instrument industry such as Piano manufacturing includes industries that reduce waste by improving the manufacturing system. The company’s strategy to eliminate this waste is to create an effective and efficient work system. The piano production process still has several problems, such as the presence of waste. This is an obstacle in improving the quality of production by reducing the waste that occurs. For this reason, this research focuses on improving the quality of production by reducing waste that occurs, finding the cause of the problem and taking corrective action. The method used in this research is the integration of Lean and Six Sigma and the DMAIC framework. The process is waste flow and production problems are identified in Define phase and residual measurement is measured in Measurement phase. Fishbone diagrams and the application of FMEA are used to analyze the factors that cause problems that occur and prioritize improvements to solve these problems. The implementation of Value Stream Mapping (VSM) is applied to the Enhance of quality improvement phase to reduce waste. The results showed that product quality increased from an average sigma level of 3.53 to 3.79 where overproduction decreased by 41% and Side Board production leadtime decreased by 373 second.

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Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Cited by 16 publications

References 20 publications

Application of lean six sigma methodology to improve the weight inconsistency problem of coffee powder packaging

Application of lean six sigma methodology to improve the weight inconsistency problem of coffee powder packaging

Implementation of the Dmaic Approach for Quality Improvement at the Elastic Tape Industry

Enhance quality improvement through lean six sigma in division Side Board Clavinova Piano’s

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