Identification Defect Cause Using the Six Sigma Method and Designing the Improvement: A Case Study
Febriana Wurjaningrum (a*), Diva Irma Nisa (a)

(a)Department of Management, Faculty of Economics and Business, Universitas Airlangga,
febriana.w[at]feb.unair.ac.id.

Abstract

A production process in a company is required to produce effectively and efficiently and also provide good quality to consumers. But in every process of production is still going on defect often lead to less efficient production process. The purpose of this study is to know the production process for the bottled mineral water, to detect the defect causes and to propose an improvement design in producing the bottled mineral water at PT. Surya Prima Cipta Mandiri, Madiun, East Java, by using Six Sigma method. This study used descriptive qualitative approach with several data collection steps, both primary and secondary data.
The result of the research was that in the production process of the bottled mineral water, there were three types of defect which became the critical-to-quality (CTQ) keys. The types of defect were (1)closed lidcup with perfect, (2)standardized product form and (3)cleanliness of product lidcup awake. The value of performance of PT. Surya Prima Cipta Mandiri in 2016 had sigma 2.91 to 3.92. Based on the Pareto Diagram, there was known the most common cause of defects. Then it could be found the factors of defect causes by using Cause and Effect Diagram. Furthermore, the FMEA analysis used to look for the source of the defect that would be the priority improvement to reduce the failure. The last analysis was using Deming Wheel to provide a proposed improvement design for the factors that have been identified. The company management is expected to implement the improvement design in order to achieve a zero defect in the production process.

Keywords: Six Sigma, improvement design, Quality Control, Defect, Critical-To-Quality, Pareto Chart, Cause and Effect Diagram, Failure Mode Effect Analysis, Deming Wheel

Topic: Innovation, IT, Operations and Supply Chain Management