Quality improvement with PDCA approach and design of experiment method in single socks industry in Indonesia

Kurnia, Hibarkah; Jaqin, Choesnul; Purba, Humiras Hardi

doi:10.1063/5.0080179

Cited by 3 publications

(3 citation statements)

References 23 publications

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“…Then, the control chart data will appear graphically in quantities adjusted to the data input [26]. As for calculating the average defect value (𝑝̅ ) or Control Limits (CL), 𝑛 is the amount of production per month, the Upper Control Limit (UCL), and the Low Control Limit (LCL) can be used by the formula ( 12), (13), and (14).…”

Section: Control Stagementioning

confidence: 99%

“…Painting is important if carried out with the Standard Operational Procedure (SOP), standards for using paint mixtures, and methods of spraying paint materials onto four-wheeled vehicle bodies [12]. Several studies have examined product failures due to operators not working according to existing SOPs [13]. Some of these product failures immediately become waste, and some are reworked, meaning there are additional costs to improve the defect [14].…”

Section: Introductionmentioning

confidence: 99%

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Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach

Zulkarnaen,

Kurnia,

Saing

et al. 2023

j. sist. manaj. ind.

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The current era provides challenges for several automotive industries to be able to compete and maintain the quality of their products. For four-wheeled automotive companies, satisfying customers regarding the visual appearance of the vehicle body is very important. However, internally, automotive companies still found many defects or failures in painting, amounting to 32.6%. Apart from that, rework also results in additional costs that the company must incur during the painting process. This study aims to clarify types of painting defects, analyze root causes, provide solutions, improve process capabilities, and increase the sigma level in the painting process in the four-wheeled vehicle industry. This study uses the Lean Six Sigma method, which is integrated into the DMAIC approach and other improvement tools. As a result, this study clarifies four critical defects in the orange peel defects of the painting section, craters, melting, and blur. This study has resulted in several corrective action solutions, including tightening supervision of the performance of painting section operators so that they are consistent and committed to working according to the Standard Operational Procedure (SOP) or work instructions that have been created. A competency matrix is used to evaluate operator performance, which is reported to superiors and subordinates by the supervisory department. After carrying out corrective action, this study increased the process capability from 1.17 to 1.92. The higher the capability value, the higher the sigma level. This study also has increased the sigma level from 2.76 to 3.42, meaning an increase of 78%. .

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Section: Control Stagementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach

Zulkarnaen,

Kurnia,

Saing

et al. 2023

j. sist. manaj. ind.

Self Cite

View full text Add to dashboard Cite

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“…specific components) in mind [28]. Improvements at this stage evaluate the production section against production targets and the production process and report what activities are carried out and the results, check again whether they have been carried out or not, and whether are they following existing standards [29]. An explanation of data on the use of local KC-04 cleaning agents in 2022 can be seen in Table 3.…”

Section: Measurementmentioning

confidence: 99%

Combination of lean thinking and A3 problem-solving methods to reduce the cost of purchasing cleaning agents in a paint manufacturer in Indonesia

Kurnia,

Juliantoro,

Suhendra

et al. 2023

Sinergi

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One of the manufacturing industries for making solvent-based and water-based paints is located in the Cikarang area, West Java. This paint company is experiencing an increase in production due to a large number of requests for various products. The company's level of cleanliness in maintaining quality and reducing waste of operational costs is the key to the company's success in becoming an international standard company. Every year the company incurs the cost of purchasing a cleaning agent imported from Norway because it is a basic requirement in material inventory to meet customer satisfaction. The purpose of this research is to reduce the wasted costs of purchasing cleaning agents originating from imports, maintaining 5S conditions, and fulfilling customer satisfaction. The method used in this study is a combination of the lean thinking method and the most effective A3 problem-solving method which can help create consistent, clear, and structured problem-solving documentation. This research found that there is a very large cost to buy a cleaning agent in 2021 of IDR 114,331,430 which must be spent by companies in using cleaning agents. The results of this study found that there was a reduction in the cost of purchasing a cleaning agent in 2022 to IDR 4,897,900. Therefore this paint company gets operational cost savings in purchasing cleaning agent materials of 97.71%.

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Analisis Pemilihan Pemasok Tanah Liat Dalam Perbaikan Kualitas Pada Umkm Kerajinan Gerabah

Hardono,

Dewa,

Kurnia

2023

Teknik Industri

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Dalam memilih dan membeli tanah liat, Usaha Mikro Kecil dan Menengah (UMKM) kerajinan gerabah memiliki empat pemasok tanah liat yang berlokasi di Provinsi Daerah Istimewa Yogyakarta. Seiring berjalannya pembelian bahan baku tanah liat, muncul masalah terkait kualitas tanah liat. Masalah tersebut adanya pemasok tanah liat yang memberikan kualitas tanah liat tidak ulet dan sulit dibentuk yang mengakibatkan penurunan kualitas produk gerabah dan terjadinya peningkatan biaya produksi karena melakukan pembelian tanah liat kembali. Penelitian ini bertujuan untuk memilih prioritas pemasok tanah liat yang memiliki kualitas bahan baku yang baik dan membuat usulan desain Standar Operational Procedure (SOP) pengadaan bahan baku gerabah yang dapat meningkatkan kualitas produk dan mengurangi biaya produksi. Penelitian ini menggunakan kombinasi metode yaitu metode kaizen berupa diagram Pareto dan diagram Fishbone dalam menganalisa permasalahan yang muncul. Kemudian pada tahap pengolahan data, metode yang digunakan adalah metode Analytical Hierarchy Process (AHP) yang multi kriteria untuk menentukan kualitas bahan baku dari empat pemasok dengan bantuan dua responden yang merupakan ahli dibidang pembelian bahan baku. Penelitian ini telah membuat desain SOP pengadaan barang pada departemen produksi UMKM gerabah. Hasil dari penelitian ini berupa urutan prioritas pemasok tanah liat yang memiliki nilai bobot tertinggi dari hasil pengolahan data dengan metode AHP yaitu, yang pertama pemasok GE (0,5814), yang kedua adalah pemasok KA (0,1890), kemudian pemasok GD (0,1246), dan yang terakhir adalah pemasok MA (0,1051). AbstractIn selecting and purchasing clay, Micro, Small and Medium Enterprises (MSMEs) for pottery crafts have four clay suppliers located in the Special Region of Yogyakarta Province. As the purchase of clay raw materials progresses, problems arise regarding the quality of the clay. The problem is that there are clay suppliers who provide quality clay that is not ductile and difficult to form, which results in a decrease in the quality of pottery products and an increase in production costs due to repurchasing clay. This research aims to select priority clay suppliers who have good quality raw materials and make a design proposal for a Standard Operational Procedure (SOP) for the procurement of pottery raw materials that can improve product quality and reduce production costs. This research uses a combination of methods, namely the kaizen method in the form of Pareto diagrams and Fishbone diagrams in analyzing problems that arise. Then at the data processing stage, the method used was the multi-criteria Analytical Hierarchy Process (AHP) method to determine the quality of raw materials from four suppliers with the help of two respondents who were experts in the field of purchasing raw materials. This research has created an SOP design for procurement of goods in the pottery MSME production department. The results of this research are in the form of a priority order for clay suppliers that have the highest weight value from the results of data processing using the AHP method, namely, the first is the GE supplier (0.5814), the second is the KA supplier (0.1890), then the GD supplier (0.1246), and the last one is the MA supplier (0.1051).Keywords: analytical hierarchy process; kaizen; supplier selection; clay; MSMEs

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Quality improvement with PDCA approach and design of experiment method in single socks industry in Indonesia

Cited by 3 publications

References 23 publications

Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach

Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach

Combination of lean thinking and A3 problem-solving methods to reduce the cost of purchasing cleaning agents in a paint manufacturer in Indonesia

Analisis Pemilihan Pemasok Tanah Liat Dalam Perbaikan Kualitas Pada Umkm Kerajinan Gerabah

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