Track: Six Sigma

Abstract

To survive in today's increasingly stringent manufacturing market, every business must strengthen its production quality control. PT. ABC is a manufacturer specialized in offset printing and packaging, and one of its products is the duplex cardboard AA duplex carton packaging. The objective of this study was to reduce the occurrence of the highest types of defects and improve production quality using the six-sigma method through the DMAIC stages (Define, Measure, Analyze, Improve, and Control) and in the improve stage using multiple tools from the seven new quality tools method to recommend improvement proposals. Based on the outcomes of data analysis and processing, the three most common forms of defects are 58.9% unclean ink, 17.3% pond tilt/run, and 12.6% spot faults. The calculation yielded Cp values of 0.84, CpK values of 0.60, DPMO values of 5861.14, and sigma level values of 4.02. After doing FMEA analysis and implementing seven new quality tools, it was determined that the biggest causal variables for each type of defect were associated with subpar production machine parts. The recommended changes are routine maintenance of industrial machinery, increased monitoring of production, and enhancements to standard operating procedures.