Abstract

This research focuses on plastic sacks produced by a plastic recycling company. The company is a manufacturing company in the recycling industry that produces plastic seeds and plastic sacks. This research identifies defects or shortcomings in the plastic sack production process. The purpose of this study is to identify and analyze the causes of product defects during the production process. Furthermore, improvement proposals will be given to reduce product defects in the production process. The method that will be used in this research is the six sigma method using DMAIC tools (define, measure, analyze, improve, control). The average production produces 20,404 kg of plastic sacks in a period of 6 months, with a defect rate of 3.12% of total production. Defects in the production process include defects in raw materials and loose stitches. Based on the calculation of Defects Per Million Opportunities (DPMO), the sigma level was found to be 3.59. An RPN value of 252 was also obtained for the detached stitch defect from the FMEA analysis. The cause of the production defect is the shifting of the bag weaving machine from its weaving groove. This research is expected to provide benefits by reducing the number of defects that occur during the production process in the company.

Keywords
Quality Control, Six Sigma, DMAIC (define, measure, analyze, improve, control), Defects Per Million Opportunities (DPMO), Failure Mode and Effect Analysis (FMEA)