Reducing the nonconforming products by using the Six Sigma method: A case study of a polyes-ter short cut fiber manufacturing in Indonesia

Syafwiratama, Oky; Hamsal, Mohammad; Purba, Humiras Hardi

doi:10.5267/j.msl.2016.12.001

Cited by 16 publications

(8 citation statements)

References 13 publications

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“…Six sigma is one of the quality control methods used in statistical analytics. Six sigma approach consists of 5 cycles that are defined, measure, analyze, improve and control or usually called DMAIC, and used to quality improvement strategy [9,12].…”

Section: Methodsmentioning

confidence: 99%

Coconut Sugar Quality Control Analysis of Home-Industry in Central Java

et al. 2021

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Coconut sugar is a potential trade commodity, and Indonesia is one of the biggest exporters in the world. There were some problems such as the use of raw material was not optimum and some quality issues. The study aims to identify the defective product and evaluate the current process capacity at Ngudi Lestari as one of the biggest home-industry in Central Java. The method was use the Six Sigma Method through DMAIC tools. The data was used primary data from 28 times production during seven days through the observation process. The finding showed that there were nine potential critical to quality that affects sugar. The control chart showed that production in Ngudi Lestari still uncontrollable. It was indicated by the process that out of control limit was about 75%. The result of the sigma value was sufficient, which was 4.39. It had reached the average sigma level of industry in the United States. The defective products were caused by raw materials, labor, equipment, and production process. The raw material was one factor that had a significant effect on the quality of coconut sugar.

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Section: Methodsmentioning

confidence: 99%

Coconut Sugar Quality Control Analysis of Home-Industry in Central Java

et al. 2021

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“…By applying DMAIC using a statistical approach, the root causes of the problem can be found and can improve the production process. The results of the six sigma improvement show the process capability increased from 2.2 to 3.1 sigma, saving $18,394.2 per month [24]. Six sigma is a systematic, flexible, measurable and effective method in solving various problems in the industrial world [25].…”

Section: Methodsmentioning

confidence: 99%

Improve Quality Remanufacturing Welding and Machining Process in Indonesia Using Six Sigma Methods

Saryanto¹,

Purba²,

Trimarjoko³

2020

JESA

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Welding and machining processes for Lift Arm Repair in Remanufacturing heavy-duty companies in Indonesia has produced parts according to customer specifications, but the company still has the intention to reduce the level of damage and Cost of Poor Quality. The purpose of this study is to demonstrate the application of the Six Sigma method with the DMAIC cycle (Define, Measure, Analyze, Improve and Control). Other tools to analyze this problem are the Pareto Diagram and the Cause and Effect Diagram. The level of product defects in the Lift Arm Remanufacturing process is relatively high, namely 73.5% over the past 5 months with the categories of Miss Alignment (68.5%), Porosity (18.9%), Crack (4.5%), Oversize (2.7%) Scratches (2.7%) and Others (2.7%). with a value of 834586.47 DPMO and is at 1.91 sigma with a COPQ of Rp.650,800,000.00. The Six Sigma approach with the DMAIC method is a systematic method that focuses on improving processes. From the DMAIC method, it can be known the factors that cause defect miss alignment and porosity through the cause diagram. After Six Sigma implementation, the level of defective products decreased from 73.5 to 7.03% with an increase in quality from 1.91 to 2.43 Sigma. Finally, we can reduce COPQ from IDR 650,800,000 to IDR 135,000,000 or 66.47% from the previous condition.

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“…Sigma value in milk processing increased to 4.79 [5], Ice cream producer has 2.43 [11], feed grain has DPMO 6734.13 [9], Tobacco industry got increment 3.72 to 3.97 [23], the cigarette industry has 2.676 [32], bagging process of sugar refinery got 5.1 sigma [35] and Crude Palm Oil (CPO) obtained Cpk 0.37 with 1.10 sigma value [39]. The third most research is textile with 6 (six) articles containing research in carded combed yarns [20], bag factory [29], fiber [37], shoe industry [51], [33] and polyester [3]. Carded and combed yarns factory got sigma level at 4 and 7786 DPMO [20], bag factory gained sigma level from 3.61 to 3.86 [29], fiber producer improve Sigma 2.2 to 3.1 [37], shoe industry in Bandung achieved sigma level 3.274 with DPMO 38758.87 [51], shoe pressing processing with sigma value 3.81 [33], a polyester industry with a DPMO value of 233 and a six-sigma level of 5 [3].…”

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confidence: 99%

“…The third most research is textile with 6 (six) articles containing research in carded combed yarns [20], bag factory [29], fiber [37], shoe industry [51], [33] and polyester [3]. Carded and combed yarns factory got sigma level at 4 and 7786 DPMO [20], bag factory gained sigma level from 3.61 to 3.86 [29], fiber producer improve Sigma 2.2 to 3.1 [37], shoe industry in Bandung achieved sigma level 3.274 with DPMO 38758.87 [51], shoe pressing processing with sigma value 3.81 [33], a polyester industry with a DPMO value of 233 and a six-sigma level of 5 [3].…”

mentioning

confidence: 99%

Six Sigma Implementation in Indonesia Industries and Businesses: A Systematic Literature Review

Widjajanto

Purba

2021

JEMIS

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Understanding quality in manufacturing starts with defect identification and improvement finding. Reliability that influenced by equipment design or working methods or environment has led to concept of improvement with six sigma method and this has been absorbed in Indonesia industries as well. This article discusses about six sigma implementation in Indonesia from various business and industries. The method is to review research articles that are published within 2016-2020 with keyword DMAIC and six sigma. The results from 52 selected articles is obtained average 3.68 sigma value of Indonesia industries within year 2016-2020 with the least value 1.10 from crude palm oil refinery and the highest is 5.10 from bagging process of sugar refinery. However, six sigma application is not always satisfying concerning its suitability function, requirement of industries, culture, local regulation, and internal business concern, especially in terms of efficiency and cost. Future research is suggested utilizing industry 4.0 concept to enhance six sigma implementations.

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Reducing the nonconforming products by using the Six Sigma method: A case study of a polyes-ter short cut fiber manufacturing in Indonesia

Cited by 16 publications

References 13 publications

Coconut Sugar Quality Control Analysis of Home-Industry in Central Java

Coconut Sugar Quality Control Analysis of Home-Industry in Central Java

Improve Quality Remanufacturing Welding and Machining Process in Indonesia Using Six Sigma Methods

Six Sigma Implementation in Indonesia Industries and Businesses: A Systematic Literature Review

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