scholarly journals Implementasi Six Sigma untuk Perbaikan Produk Nickel Pig Iron

2017 ◽  
Vol 1 (1) ◽  
pp. 29
Author(s):  
Mohamad Jihan Shofa ◽  
Hadi Gunawan
Keyword(s):  
Six Sigma ◽  
Raw Materials ◽  
Pig Iron ◽  
New Materials ◽  
Steel Mill ◽  
Upward Trend ◽  
Mining Company ◽  
Effect Analysis ◽  
Sigma Level ◽  
Iron Nickel

PT. INF is a steel mining company. It produce such as nickel pig iron. Nickel pig iron used raw materials stainless steel factory, nickel and steel mill rolls. The number of defective products for nickel pig iron in a few months getting on upward trend. This research will analyze the cause of the increasing defect product by using Six Sigma methode. Furthermore, the proposed improvement is done by using the failure mode and effect analysis (FMEA) approach. The results shows the main problems are the higher value of Silica (Si) and phospor (P), the sigma level is obtained from the annual pig iron making process in 1.6 sigma, process improvement need to be done are monitoring and scheduling of burnlime powder orders, checking new materials by testing the formula against new materials, and making a repair schedule as well as focusing on changes in pressure on the monitor screen

scholarly journals Usulan Pengendalian Kualitas Produksi Benang Carded dengan Metode Six Sigma

2018 ◽  
Vol 4 (1) ◽  
pp. 38
Author(s):  
Abdul Manan ◽  
Firdanis Setyaning Handika ◽  
Ahmad Nalhadi
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Six Sigma ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Sigma Level ◽  
Mode Effect ◽  
Target Set ◽  
Failure Mode Effect Analysis

A yarn company strives to produce good and quality products, but the production process that is carried out by each person will produce products targeted at a target that has been set at 5%. This study uses the Six Sigma method but only until the improvement stage. The research is to determine the DPMO value and sigma level in the spinning production process, to know what factors cause defects and new parameters to reduce the defect. Based on the results of the study that the DPMO on the type of CD thread in the spinning section is 17,130 and the sigma level is 3,6. The level of sigma that has dominated the Indonesian industry average, but has a defect of 8.7%, the target set at 5%. Damaged and dirty apron, clogged trumpet, and leaky hose are factors that plan defects. Furthermore, with Failure Mode Effect Analysis (FMEA), the highest value of Risk Priority Number (RPN) in tangled defects is that the apron is damaged (140) and clogged trumpet (120), while the highest RPN value is gross dirty, i.e., dirty apron (150) and hose leaking lubricant (120).

scholarly journals Analisis Pengendalian Kualitas menggunakan Metode Six Sigma pada Produk Roti Tawar di PT. Ital Fran’s Multindo Food Industries Cabang Bali

2020 ◽  
Vol 8 (4) ◽  
pp. 587
Author(s):  
Ketut Lilis Setiawati ◽  
I Ketut Satriawan ◽  
I Wayan Gede Sedana Yoga
Keyword(s):  
Six Sigma ◽  
Raw Materials ◽  
Employee Performance ◽  
Standard Operating Procedures ◽  
White Bread ◽  
Bread Making ◽  
Food Industries ◽  
Sigma Level ◽  
Standard Operating ◽  
Control Limits

The purpose of this study were to determine the factors of damage, to analysis of damage is still within control limits and to establish efforts to repair damaged bread products at PT. Ital Fran's Multindo Food Industries. Data analysis used the six-sigma method, with the stages of Define, Measure, Analyze, Improve (DMAI). The results of this study are the factors that cause product damage come from human factors, production machines, work methods and materials / raw materials. Damage to white bread products at PT. Ital Fran's Multindo Food Industries is in control limits or has good process capabilities. The average Defects Per Million Opportunities (DPMO) value was 3107.3874 and the average sigma value was 4.24, including sigma level 6. Proposed improvements that can be done to overcome damage to plain bread products, namely making Standard Operating Procedures for laying bread from the pan to the conveyor, monitoring and checking employee performance, making Standard Operating Procedures regarding the right temperature and standard time for removing bread, making Operational Standards Procedures regarding cleanliness in the production area and worker hygiene, carry out maintenance and cleaning of tools and machines on a regular basis. Keywords : quality control, six sigma, white bread

scholarly journals PRODUCT QUALITY CONTROL USING SIX SIGMA (DMAIC) METHODS TO MINIMIZE WAST IN BIMA MANDIRI CIGARETTE COMPANY REMBANG, PASURUAN REGENCY

2021 ◽  
Vol 2 (2) ◽  
pp. 14-22
Author(s):  
Muhammad Husen ◽  
Dayal Gustopo ◽  
Dimas Indra Laksmana
Keyword(s):  
Quality Control ◽  
Six Sigma ◽  
Raw Materials ◽  
Sigma Level ◽  
Regular Control ◽  
Machine Operators ◽  
Engine Components ◽  
A Company ◽  
Regular Training

Quality is a key to be able to compete in the industrial world [16. Quality control is needed to reduce the number of defective products produced by the company, thus reducing losses experienced by the company. The Bima Mandiri Rembang Pasuruan cigarette company is a company that produces cigarettes, one of which is INNO cigarettes. The number of defective products produced by the company so that the company must make an increase in quality by using a method to reduce the number of defects that occur.  The number of defective products causes the company to suffer losses. For that, we need a method that can reduce cigarette defective products which in turn can improve the quality of the company's production[12]. Six Sigma with the DMAIC stage (Define, Measure, Analyze, Improve, Control) is a method used in this research. Based on these steps, defects that often occur are less dense cigarettes as many as 289 sticks with a percentage of 25%, tearing on the cigarettes as many as 227 cigarettes with a percentage of 20% and peeling cigarettes as many as 208 sticks with a percentage of 18%. Factors that cause defects include humans, machines, methods and materials. After calculating using the Six Sigma method, before the improvement, the DPMO value is 113988.1 and the Sigma Level value is 2.722. After the improvements were made, the DPMO value decreased to 76488.1 and the Sigma Level was 2.94715. To achieve the six sigma target, the company is expected to be able to carry out improvements with a focus on the factors that cause product defects and always carry out regular control to reduce product defects. The corrective steps taken in the Bima Mandiri Rembang Pasuruan Regency cigarette company are human: regular training for machine operators and employees; methods: inspection of raw materials, blending machines and glue residue in the teat; engine: inspection of engine components; material: reprocessing less refined raw materials and using better quality glue.

scholarly journals Analisis Pengendalian Kualitas Cacat Produk Kaleng 307 di PT.X Menggunakan Metode Six Sigma

2019 ◽  
Vol 12 (2) ◽  
pp. 52
Author(s):  
Qoyinul Amin ◽  
Dedi Dwilaksana ◽  
Nasrul Ilminnafik
Keyword(s):  
Problem Solving ◽  
Production Process ◽  
Six Sigma ◽  
Raw Materials ◽  
Machine Maintenance ◽  
Sigma Level ◽  
Production Area ◽  
The Right ◽  
Engine Maintenance ◽  
Damaged Materials

Pengendalian kualitas merupakan sebuah teknik yang dapat dilakukan mulai dari tahap sebelum proses produksi hingga proses produksi berakhir. Six sigma merupakan sebuah metodologi terstruktur untuk memperbaiki proses dengan menggunakan statistik dan problem solving tools secara intensif menuju target 3,4 kegagalan per satu juta kesempatan. PT. X bergerak di bidang industri pembuatan kaleng makanan dengan salah satu produknya adalah kaleng tipe two piece cans 307. Berdasarkan informasi perusahaan, pada proses produksi kaleng tipe tersebut seringkali ditemukan produk mengalami cacat yang merugikan perusahaan. Penelitian ini dilakukan untuk mengetahui bagaimana cara yang tepat untuk meminimalkan cacat kaleng tipe tersebut dengan menggunakan metode six sigma. Hasil penelitian diketahui bahwa penyebab utama cacat adalah pekerja kurang teliti, setting clearence dies yang terlalu rapat, dies kemasukan afval, pisau press tumpul, bahan kotor dan rusak, perawatan mesin yang tidak dilakukan secara berkala, area produksi tidak rapi dan bising. Nilai DPMO sebesar 2844 yang dikonversikan kedalam sigma level yakni 4.27. Usulan perbaikan dengan Five-M Checklist meliputi memberikan pelatihan dan memperketat pengawasan kepada pekerja, melakukan setting mesin sesuai prosedur serta ubah clearence dies menjadi 0,24 mm, memperketat pemeriksaan bahan baku kaleng, melaksanakan perawatan mesin sesuai dengan jadwal yang telah ditentukan, menjaga kebersihan dan kerapian area produksi. Quality control is a technique that can be carried out from before the production process until the production process ends. Six sigma is a structured solution to process improvement using statistics and problem solving tools that intensively reach the target of 3.4 recovery per one million opportunities. PT. X is engaged in the industry of making cans with one of its products is a 307 two-piece can. Based on company information, in the production process, cans are found to find products that can save the company. This research was conducted to find out the right way to overcome this type of defect by using the six sigma method. The results of the study are known to be related to the fact that workers do not have meticulous, clear dead settings that are too tight, afval conceded dies, blunt press blades, dirty and damaged materials, machine maintenance that is not officially done, production area is not neat and noisy. The DPMO value is 2844 which is converted into sigma level which is 4.27. Proposed improvements with the Five-M Checklist provide training and tighten supervision to workers, make machine arrangements according to procedures and change clearly to 0.24 mm, tighten inspection of tin raw materials, manage engine maintenance according to agreed schedules, care about cleanliness and neatness production area.

scholarly journals Penerapan Metode Six Sigma untuk Menurunkan Jumlah Defect pada Produksi Fillet Ikan Kakap Putih (Lates Calcarifer bloch)

2021 ◽  
Vol 9 (1) ◽  
pp. 35
Author(s):  
Putu Ayu Aripradnyani ◽  
I Wayan Widia ◽  
I Gusti Ketut Arya Arthawan
Keyword(s):  
Production Process ◽  
Performance Improvement ◽  
Six Sigma ◽  
Raw Materials ◽  
Production Costs ◽  
Production Cycle ◽  
Management Process ◽  
Critical Factors ◽  
Sigma Level ◽  
Co Gas

ABSTRAK Setiap perusahaan seyogyanya berupaya memperkecil resiko kegagalan dalam berproduksi. Tingginya persentase produk defect dalam setiap siklus produksi selain berimplikasi terhadap menurunkan kepercayaan konsumen juga menaikkan biaya produksi sehingga berakibat menurunkan daya saing produk di pasar. Tujuan penelitian ini adalah mengidentifikasi faktor kritis penyebab defect pada produk dan menemukan bentuk perbaikan kinerja dalam proses manajemen yang dapat dilakukan untuk mengurangi jumlah produk defect pada proses produksi fillet ikan kakap putih kualitas ekspor pada salah satu perusahaan pengolahan ikan di Bali menggunakan metode six sigma. Penelitian ini mencakup lima tahapan implementasi six sigma yaitu DMAI (Define, Measure, Analyze, dan Improve) yang melibatkan pihak manajemen dan karyawan perusahaan. Hasil penelitian menunjukkan bahwa terindentifikasi dua faktor kritis penyebab tertinggi dari enam kategori defect fillet ikan kakap putih. Karakteristik kinerja yang dicapai oleh perusahaan saat ini dicirikan oleh angka DPU (Defect per Unit) sebesar 0,09, DPO (Defect per Opportunities) sebesar 0.045, DPMO (Defect per Million Opportunities) sebesar 45,463 yang setara dengan kinerja pada level 3,125-Sigma sehinga tergolong dalam kategori tingkat kinerja rata-rata industri. Perusahaan berpotensi meraih peningkatan kinerja hinga pada level 4,000-Sigma sepanjang bersedia melakukan sejumlah perbaikan secara berkesinambungan dalam manangani baik terhadap pengawasan mutu bahan baku ikan maupun ketidaksempurnaan pemberiaan gas CO pada produk. Dengan penerapan metode six-sigma, maka faktor kritis penyebab defect tertinggi yang ditemukan yakni daging pecah/lembek dan berbau serta pemberian gas CO yang kurang merata sehingga bentuk perbaikan kinerja dalam proses manajemen yang direkomendasikan adalah menjalankan formulir checklist pada setiap proses produksi, memberikan pelatihan-pelatihan bagi karyawan dan melakukan pemeriksaan terhadap kemasan. ABSTRACT Every company should try to minimize the risk of failure in production. The high percentage of defective products in each production cycle has implications not only reducing consumer confidence but also increasing production costs, which results in lower product competitiveness in the market. The objective of this study was to identify the critical factors that cause defects in the product and find a form of performance improvement in the management process that can be done to reduce the number of defect products in the export quality white snapper fillet production process at a fish processing company in Bali using the six-sigma method. This research consisted of Six-Sigma implementation stages, namely DMAI (Define, Measure, Analyze, and Improve) which involved management and company employees. The results showed that two critical factors were identified as the highest cause of the six categories of white snapper fillet defects. The performance characteristics achieved by the company are currently characterized by a DPU (Defect per Unit) number of 0.09, DPO (Defect per Opportunities) of 0.045, DPMO (Defect per Million Opportunities) of 45.463 which is equivalent to performance at the 3,125-Sigma level so that belongs to the category of industry average performance level. The company has the potential to achieve an increase in performance up to the 4,000-Sigma level as long as it is willing to make a number of continuous improvements in handling both the quality control of fish raw materials and imperfections in the supply of CO gas in the product. With the application of the six-sigma method, the critical factors causing the highest defects were broken / mushy and smelly meat and uneven distribution of CO gas so that the recommended form of performance improvement in the management process was running a checklist form at each production process, providing training for employees and conducting an inspection of packaging.

scholarly journals Analisa kinerja bongkar muat dengan lean six sigma untuk mengurangi demurrage di pelabuhan PT. Petrokimia Gresik

2020 ◽  
Vol 19 (2) ◽  
pp. 105-114
Author(s):  
Ni’matus Syajarotul Aliyah ◽  
Yugowati Praharsi ◽  
Danis Maulana
Keyword(s):  
Six Sigma ◽  
Research Method ◽  
Raw Materials ◽  
Lean Six Sigma ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Self Interest ◽  
Loading And Unloading ◽  
Operational Activities ◽  
And Control

PT. Petrochemical Gresik is one of the firms that has a terminal to be operated by own company (Terminal for Self-interest / TUKS) which supports the activity of unloading raw materials for production and loading activities to load production results. However, in carrying out its operational activities, it still causes demurrage which is a penalty that must be paid by the shipper to shipowner because it exceeds the time limit agreed in the contract of the ship. In this study, an analysis will be carried out on how to identify waste, analyze the causes of waste in the loading and unloading performance of the ship, and analyze how to minimize the factors causing demurrage in TUKS PT. Petrochemical Gresik. The research method used is lean six sigma by integrating the concept of lean process (7 waste) to the six sigma tools namely DMAIC (Define, Measure, Analyze, Improve, and Control). The results of the research at the define phase can be identified into twenty-one CTQ (Critical to Quality) with the highest waste value, namely the internal equipment breakdown category which will only be analyzed further. Subsequently, the measurement phase is identified by the value of DPMO (Defect per Million Opportunities) and six sigma capabilities. Furthermore, the analyze phase is done by finding the root of the problem using fishbone diagrams and FMEA (Failure Mode and Effect Analysis) to attain the value of RPN (Risk Priority Number) and the highest five RPN values. One out of the five causes that are recommended to be prioritized in the handling is operators do not work according to SOP. Finally, in the improvement phase, the new SOP from the results of discussions / interviews was made with the expert judgment related to the operation of the unloading equipment at TUKS PT. Petrochemical Gresik. By this study, lean six sigma can be applied to minimize the occurrence of demurrage by PT. Petrochemical Gresik and other industrial ports.

scholarly journals Integration of value stream map and strategic layout planning into DMAIC approach to improve carpeting process

2017 ◽  
Vol 10 (1) ◽  
pp. 74 ◽  
Author(s):  
Ayman Nagi ◽  
Safwan Altarazi
Keyword(s):  
Six Sigma ◽  
Control Charts ◽  
Process Capability ◽  
Poor Quality ◽  
Value Stream Mapping ◽  
Effect Analysis ◽  
Pareto Analysis ◽  
Value Stream ◽  
Sigma Level ◽  
Strategic Layout

Purpose: This paper presents an implementation of the Six Sigma DMAIC approach implementing lean tools and facilities layout techniques to reduce the occurrence of different types of nonconformities in the carpeting process. Such carpeting process can be found in several industries such as construction, aviation, and automotive.Design/methodology/approach: The improvement process was built through a sequential implementation of appropriate interconnected tools at each phase of the DMAIC approach. Utilized tools included: Pareto analysis, control charts, Ishikawa chart, 5-whys, failure mode and effect analysis, process capability ratio, value stream mapping, and strategic layout planning.Findings: The carpeting process capability, quality of the product, customer satisfaction, and cost of poor quality were significantly improved. Explicitly, the sigma level was improved from 2.297 to 2.886 and the defects per million opportunities (DPMO) was reduced from 21615 to 3905.Originality/value: This paper has approved the capability of the Six Sigma DMAIC approach to analyze, investigate, and remove the root causes of the carpeting (preparation-installation) process nonconformities .

scholarly journals Application of Six Sigma Using DMAIC Methodology in the Process of Product Quality Control in Metallurgical Operation

2017 ◽  
Vol 20 (4) ◽  
pp. 104-109 ◽  
Author(s):  
Lenka Girmanová ◽  
Marek Šolc ◽  
Juraj Kliment ◽  
Adriana Divoková ◽  
Vojtech Mikloš
Keyword(s):  
Quality Control ◽  
Product Quality ◽  
Six Sigma ◽  
Analysis Data ◽  
Product Quality Control ◽  
Safety Level ◽  
Effect Analysis ◽  
Sigma Level ◽  
Tools And Techniques

Abstract The Six Sigma DMAIC can be considered a guide for problem solving and product or process improvement. The majority of companies start to implement Six Sigma using the DMAIC methodology. The paper deals with application of Six Sigma using the DMAIC methodology in the process of product quality control. The case study is oriented on the field of metallurgical operations. The goal of the Six Sigma project was to ensure the required metallurgic product quality and to avoid an increase in internal costs associated with poor product quality. In this case study, a variety of tools and techniques like flow chart, histogram, Pareto diagram, analysis of FMEA (Failure Mode and Effect Analysis) data, cause and effect diagram, logical analysis was used. The Sigma level has improved by approximately 13%. The achieved improvements have helped to reduce the quantity of defective products and the processing costs (technology for re-adjusting). Benefits resulting from the DMAIC implementation can be divided into three levels: the qualitative, economic and safety level.

Measure and Analyze the Problems of Concrete Mixture Production via Six Sigma DMAIC Tools: Central Concrete Mix Plant as a Case Study

2012 ◽  
Vol 622-623 ◽  
pp. 472-477
Author(s):  
Ali A. Karakhan ◽  
Angham E. Alsaffar
Keyword(s):  
Six Sigma ◽  
Business Strategy ◽  
Concrete Mixture ◽  
Statistical Tools ◽  
Sigma Level ◽  
Defect Rate ◽  
Concrete Production ◽  
Concrete Mix ◽  
Six Sigma Methodology

The aims of this study are to measure the defect rate and analyze the problems of production of ready concrete mixture plant by using Six Sigma methodology which is a business strategy for operations improvement depending basically on the application of its sub-methodology DMAIC improvement cycle and the basic statistical tools where the process sigma level of concrete production in the case study was 2.41 σ.

Investigation on Shear Behaviour of Flax-Kenaf Hybrid Composite

2014 ◽  
Vol 1051 ◽  
pp. 139-142 ◽  
Author(s):  
V.S. Srinivasan ◽  
S. Rajendra Boopathy ◽  
B. Vijaya Ramnath
Keyword(s):  
Hybrid Composite ◽  
Raw Materials ◽  
Technological Development ◽  
Fiber Composites ◽  
Shear Behaviour ◽  
Biodegradable Material ◽  
New Materials ◽  
Double Shear ◽  
Environmental Friendly ◽  
Shear Property

The present technological development makes us to find and fabricate new materials to replace existing materials. Also, the need for environmental friendly, easily biodegradable material plays prime role in determining the raw materials. In this paper Flax and Kenaf fibres are used as the suspending matrix to form hybrid composite with epoxy resin. Hand layup technique is carried out in this work to fabricate composite laminate. The double shear property is evaluated. The result shows that the hybrid composite shows better property than mono fiber composites.

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