Track: Undergraduate Student Paper Competition

Abstract

The research was conducted at the packaging stage in a cement factory. Cases of product defects in cement bagging with kraft 50 type occurred from December 2021 to February 2022 with a total percentage of 7.54%. The research objective is to identify product defects and minimize waste that arises so that production is more effective and efficient. The research uses the lean six sigma method. Lean to reduce waste that occurs in the production process. Six sigma to reduce the level of defects by using the Define, Measure, Analyze, Improve, and Control stages. The stage of defining a problem with existing data to improve the process and product quality using SIPOC and CTQ diagrams. The measuring stage uses a p control chart to identify product defects, then uses DPMO calculations and sigma levels to calculate the capability of defective products with the result before repair that is 19708 with a sigma level of 3.57 sigma. mapping Value Stream Mapping and calculating Process Cycle Efficiency with the result before repair of 6.99%. The analysis phase uses an Ishikawa diagram for analysis. Proposed improvements at the repair stage are operator training, display of the 5S concept, and machine maintenance checklist. Then the control stage makes a VSM proposal by combining activities. So the calculation of the new DPMO is 11985 with a sigma level of 3757 sigma. Then the new PCE count is 7.62%.