Implementasi Pendekatan DMAIC untuk Quality Improvement pada Industri Manufaktur Kereta Api

Sumasto, Fredy; Satria, Putra Utama; Rusmiati, Emi

doi:10.30656/intech.v8i2.4734

Cited by 8 publications

(11 citation statements)

References 13 publications

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“…Defective products can also result in decreased customer satisfaction and result in losses for the company. To improve product quality, manufacturing companies can use several tools and methods, such as DMAIC (Kulkarni et al, 2022;Ranade et al, 2020;Sumasto et al, 2022), PDCA (Khaerudin & Rahmatullah, 2020;Sunadi et al, 2020;Utami & Djamal, 2018;Wajdi & Wiguna, 2015), Quality Tools (Manojkumar & Kumar, 2021;Prasojo et al, 2020), and Statistical Process Control (SPC) (Godina et al, 2018;Madanhire & Mbohwa, 2016;Sunadi et al, 2020). These methods can help companies identify quality problems and develop appropriate problem solutions.…”

Section: Improving the Quality Of Automotivementioning

confidence: 99%

“…If these components are not of good quality, there is a possibility that problems will occur with the vehicle, such as engine damage to accidents caused by system failures. components can help reduce defective products in an automotive component manufacturing company (Muhazir et al, 2020;Sumasto et al, 2022;Sya'roni & Suliantoro, 2017). Defective products can occur due to errors in the production process or because the materials used do not meet established standards.…”

Section: Introductionmentioning

confidence: 99%

“…Defective products can occur due to errors in the production process or because the materials used do not meet established standards. To be able to improve product quality, companies can take corrective actions such as reducing the level of defective products produced to save production costs and increase customer satisfaction (Garza-Reyes et al, 2018;Rosa et al, 2017;Sumasto et al, 2022). Based on these problems, automotive component manufacturers must pay attention to the quality of the products they produce in each production process.…”

Section: Introductionmentioning

confidence: 99%

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PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry

Sumasto,

Maharani,

Purwojatmiko

et al. 2023

IJIEM

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The research aim to reduce the potential for product defects in the automotive component industry by implementing Plan-Do-Check-Action (PDCA). The application of the PDCA method was carried out in an automotive component manufacturing company in Indonesia which produced SLJ 91 parts as a research object. The causes of the high number of product defects are known at the Plan stage from setting the theme of improvement to the root cause by using a fishbone diagram and 5W+1H analysis. In the Do stage, system improvements are implemented from the solutions generated by the 5W+1H analysis. The repair results are controlled to confirm the results of the repairs made. The corrective actions taken resulted in a reduction in product defects of 2.8% so that they were included in the maximum tolerance for the number of defects in the SLJ 91 part. Based on the results of data processing, analysis, and comparison between before and after implementation, it was found that the defect rate for SLJ 91 products was reduced from 10.8 % to 8%, a reduction in the percentage of 2.8% so that the product reaches the quality target it should be. The results of the repair had a direct impact on the type of dent defects, namely a decrease in the number of defects from 8.6% to 5.3%, so that there was a decrease of 3.3%. The results of the research are implemented and standardized in the action stage so that the improvements made can be maintained in the long term.

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Section: Improving the Quality Of Automotivementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry

Sumasto,

Maharani,

Purwojatmiko

et al. 2023

IJIEM

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“…Shearing Shearing is the process of cutting sheet iron plates into smaller parts with a shear cutting machine. This process has the aim of cutting iron plate sheets according to the required size so that they can be processed at the next stage (Sumasto et al, 2022).…”

Section: Tahap Analyzementioning

confidence: 99%

Storage Rack Design to Minimize Customer Claims at PT Rekadaya Multi Adiprima Using DMAIC, FMEA, and NIDA Methods

Aqsadewa,

Rusmiati,

Kramanandita

2023

Global

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PT Rekadaya Multi Adiprima is a manufacturing industry that produces automotive components, especially for four-wheeled vehicles. PT Rekadaya Multi Adiprima is divided into four production divisions, namely the metal division, non-woven division, plastic division (service hole), and interior division. During the implementation of production at PT Rekadaya Multi Adiprima, there was still a customer claims process which was very detrimental to PT Rekadaya Multi Adiprima. Based on the results of interviews with quality staff, it was found that the number of claims occurring in 2022 at plant 1 of PT Rekadaya Multi Adiprima exceeded the tolerance set by the company, namely 0.05%. Based on these problems, further observations need to be made to resolve existing problems. The method used to solve this problem is the DMAIC (Define, Measure, Analyze, Improve, control) method with the help of the FMEA (Failure Mode and Effects Analysis) method based on customer claim data from July 2022- December 2022. The defining stage is carried out by analysis to determine product with the highest level of claims, the measurement stage involves calculating the DPMO value and Sigma Level, the analysis stage aims to find out the cause of the claim using the help of a fishbone diagram and the FMEA Table, in the improv stage the aim is to find and make improvements with the help of the 5W+1H Table based on the diagram fishbone and FMEA tables that have been made previously. As well as carrying out design using the NIDA method, the final stage of control is monitoring the expected improvement results. The results before the improvement, the DPMO value was 77,000 units with a sigma level of 2.925 and after the improvement the DPMO value decreased to 17,400 units with a sigma level of 3.611. The results of the improvements made reduced the level of customer claims by 61.93%.

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“…In dealing with this, an effort is needed to improve human resources (HR) so that they can keep up with current developments (Chenoy et al, 2019;Pinthapataya, 2022). In addition, quality improvement based on customer demand is also a critical aspect of the manufacturing industry (Sumasto et al, 2022). In companies that produce automotive parts, an accurate measurement system is very important to ensure the quality of the products produced (Ming, 2016).…”

Section: Introductionmentioning

confidence: 99%

Implementation of Measurement System Analysis to Reduce Measurement Process Failures on Part Reinf BK6

Sumasto¹,

Nugroho²,

Purwojatmiko³

et al. 2023

IJIEM

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This study aims to reduce the failure of the measurement process on Part Reinf BK6 in the automotive industry which prioritizes accuracy and precision in the process to maintain product quality and customer satisfaction. This study used the measurement system analysis (MSA) method to analyze the Gage R&R on a measurement system, with 2 operators and 10 parts measured with 3 repetitions. The MSA results before improvement showed a Total Gage R&R of 67.80% with a repeatability value of 0.98% and a reproducibility value of 66.82%. The result indicated that the measurement system needs to be improved because the Gage R&R is still above 30%. After improving the measurement process by adding the Go No Go pin as an additional tool, the MSA results show the Total Gage R&R value after the improvement is made to 10.11% with repeatability and reproducibility values of 10.11% and 0% respectively. Based on the results of the study, it can be concluded that the improvements made have a significant effect on the measurement system on Part Reinf BK6. This will improve accuracy and precision in the measurement process, maintain product quality, and increase customer satisfaction. Therefore, improving the measurement system is very important in the automotive industry.

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Implementasi Pendekatan DMAIC untuk Quality Improvement pada Industri Manufaktur Kereta Api

Cited by 8 publications

References 13 publications

PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry

PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry

Storage Rack Design to Minimize Customer Claims at PT Rekadaya Multi Adiprima Using DMAIC, FMEA, and NIDA Methods

Implementation of Measurement System Analysis to Reduce Measurement Process Failures on Part Reinf BK6

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