scholarly journals ANALISIS PENGENDALIAN KUALITAS DENGAN MENGGUNAKAN METODE LEAN SIX SIGMA DI PT. XYZ

2021 ◽  
Vol 16 (2) ◽  
pp. 13-24
Author(s):  
Ahmad Fauzi ◽  
Moch Tutuk Safirin
Keyword(s):  
Six Sigma ◽  
Value Added ◽  
Lean Six Sigma ◽  
Value Stream ◽  
Sigma Level ◽  
Big Picture ◽  
Production Output ◽  
Fmea Method ◽  
One Machine

XYZ is a company that produces Medical Devices. One of the products produced is 16x16 hydrophilic sterile gauze. One of the factors that affect the quality of a product is the presence of defects in the product and waste which results in a longer lead time for a product. The investigative stages used in this study are using tools: seven tools, Big Picture Mapping, Value Stream Analysis (VALSAT) and then analyzing the causes of defects using the Ishikawa diagram (fishbone chart) where the output of this study is a proposed improvement using the FMEA method ( Failure Mode Effect and Analysis) to eliminate defects and waste that occur. Based on the research results, it is known that the type of waste identified by the calculation of Value Stream Activity and obtained Value Added with a percentage of 84.4%, Non Value Added by 1.0% and Necessary Non Value Added by 14.5%. From the results of production output in December 2019 to November 2020 amounting to 2,650,200 boxes, the number of defects is 1,316 boxes with an average sigma level of 5.16, while in FMEA it is known that the largest defects are spots with an RPN value of 504 and a suggestion for improvement is to place Experienced operators who have gone through the recruitment and training stages on superior qualifications on one machine according to their skills who understand SOPs and operators are given good comfort in the production process.                                                                                                   Keywords: Lean Six Sigma, Seven Waste, DMAIC, FMEA, kasa steril hidrofil 16x16.

Integration of DMAIC, VSM and Valsat to Reduce Waste in Disk Brake Cutting Process Using DMAIC, VSM and Valsat Method Approach (Case Study: Company IM)

2021 ◽  
Vol 2 (2) ◽  
Author(s):  
Muhammad Kholil ◽  
Adizty Suparno ◽  
Sulaiman Bin H Hasan ◽  
Muhammad Rizki
Keyword(s):  
Six Sigma ◽  
Spare Parts ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Depth Analysis ◽  
Production Area ◽  
Production Output ◽  
Fmea Method ◽  
Six Sigma Approach

The Company IM is a manufacturing company that produces two-wheeled automotive spare parts. One of the products currently being supplied to several two-wheeled customers is the disc brake, rear sprocket, and drive sprocket. The opportunity to increase production output adjusted to high customer demand can be done by reducing waste activities. Therefore, an approach with a lean six sigma approach is needed using the integration method of DMAIC (Define, Measure, Analyze, Improve, and Control), VSM (Value Stream Mapping), and VALSAT. This study aims to reduce production waste and reduce cycle time, affecting increasing production output to balance according to customer needs. Waste identification is explained in the Define stage at DMAIC using a big mapping image in Value Stream Mapping. A more in-depth analysis is carried out using the VALSAT tools at the Analyze stage supported by WRM and WAQ questionnaire data. The Analyze stage was then carried out by analyze using the FMEA method. Control is carried out by standardization and outreach to employees. This study aims to identify and reduce the waste in the production area, especially line-cutting disks. Based on the integration results of lean six sigma with the DMAIC, VSM, and VALSAT methods, the efficiency is obtained from 72% to 96%.

scholarly journals IMPLEMENTASI KONSEP LEAN MANUFACTURING GUNA MENGURANGI PEMBOROSAN DI LANTAI PRODUKSI

OPSI ◽  
2018 ◽  
Vol 11 (1) ◽  
pp. 14 ◽  
Author(s):  
Almer Panji Pradana ◽  
Mochammad Chaeron ◽  
Muhammad Shodiq Abdul Khanan
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Assessment Model ◽  
Value Stream ◽  
Event Simulation ◽  
Analysis Tools ◽  
Big Picture

CV Marga Jaya (Pabrik II) adalah perusahaan yang bergerak di bidang pembuatan paving/conblock secara masal. CV Marga Jaya (Pabrik II) selalu berusaha mengurangi pemborosan yang terjadi selama proses produksi paving/conblock. Pemborosan yang terjadi antari lain, adanya produksi berlebih, transportasi, waktu menunggu, dan cacat yang berlebih.  Lean Manufacaturing merupakan pendekatan yang bertujuan untuk merampingkan proses dengan mengurangi pemborosan yang terjadi selama proses produksi. Pendekatan konsep lean manufacturing dimulai dengan membuat big picture mapping, dilanjutkan dengan waste assessment model (WAM), diagram cause and effects, value stream analysis tools (VALSAT), usulan perbaikan waste yang terjadi, dan pembuatan descrete event simulation (DES). Hasil yang didapat bahwa waktu menunggu yang terjadi diperbaiki dengan menggunakan conveyor, produksi berlebih yang terjadi diperbaiki dengan melakukan perencanaan produksi, dan cacat berlebih yang terjadi diperbaiki dengan menggunakan 5W+1H dengan sebelumnya menggunakan konsep lean six sigma dan didapat nilai sigma sebesar 4,31 sigma. Simulasi proses menunjukkan dengan mengurangi pemborosan, kemampuan produksi naik 15,36% (penjemuran 30 hari) dan 147,20% (penjemuran 7 hari).

scholarly journals A Review Paper on Simulation Based Six Sigma Approach in Quality Assurance

2019 ◽  
Author(s):  
Mehreen Sirshar ◽  
Iqra Hanif ◽  
Sidra Shahzad ◽  
Muneeza Khalid
Keyword(s):  
Six Sigma ◽  
Lean Six Sigma ◽  
Production Lines ◽  
Sigma Level ◽  
Simulation Based ◽  
Quality Product ◽  
Six Sigma Approach ◽  
Critical Process ◽  
Eda Tools

The main purpose of this research is to use “DMAIC” and “DMADV” framework of six sigma to reduce cost of projects, increase yields, improve performance and reduce defects. This study conclude that the sigma level of cement bag production in four production lines is “4.7 DPMO” values of 710 and the possibility of defects per unit of 11 possibilities this situation was handled by using six sigma. Any business or industry run only to satisfy customer and increase their profits, this can be attained as development of quality product..For the ranking of newly established universities the certification of those institutes is very important and also a critical process. For this process we used Lean six sigma approach that can identify the wastes that affect this process.Six sigma can be applied to any work field such as education, power optimization and other types of industries Six sigma “DMAIC” approach is also used for the testing of EDA tools that occurs due to the complex coding or configurations, flows and platforms they support. To improve the process quality of SDLC it’s necessary to remove the defects of system in advance along with thorough valuation of size and it also makes project accordant with real time environment

scholarly journals Six Sigma as a method of improving the quality of service process

2018 ◽  
Vol 19 (19) ◽  
pp. 10-15 ◽  
Author(s):  
Kamila Kowalik
Keyword(s):  
Six Sigma ◽  
Service Process ◽  
Value Stream Mapping ◽  
Pareto Chart ◽  
Value Stream ◽  
Sigma Level ◽  
Fishbone Diagram ◽  
Mapping Process ◽  
The Impact

Abstract The objective of the analysis conducted and described in this paper has been to present the practical application of the Six Sigma method based on the DMAIC cycle in improving the quality of the service process. The first part of the article contains the theoretical framework of six sigma and the issue of using its tools in the aspect of services. Afterwards, there has been calculated the initial sigma value which indicated the need for improvement. Measurement phase has been developed by the value stream mapping, process FMEA and customer survey which results have been analyzed in Pareto chart and fishbone diagram. Improve phase includes the Impact&Effort Matrix and target sigma level that can be achieved as a result of failures reducing and service quality improvement.

scholarly journals Pemberdayaan dan Penguatan Daya Saing Usaha dengan Penerapan Lean Six-Sigma Concept, Studi Kasus

2018 ◽  
Vol 20 (1) ◽  
Author(s):  
Hari Supriyanto
Keyword(s):  
Quality Control ◽  
Six Sigma ◽  
Net Present Value ◽  
Value Added ◽  
Lean Six Sigma ◽  
Risk Priority Number ◽  
Present Value ◽  
Packaging Process ◽  
Value Stream ◽  
Root Cause

Dinamika dan perkembangan ekonomi global dapat memberikan sinyal positif terhadap pentingnya peningkatan pemberdayaan dan daya saing produk di pasar. Dibutuhkan pemikiran untuk membangun keunggulan kompetitif, yang menjadi dasar bagi peningkatan produksi dan daya saing bisnis. Peningkatan produksi merupakan serangkaian aktifitas untuk membentuk produktifitas. Bila salah satu aktifitas produksi mengalami kegagalam maka akan berpengaruh pada kualitas dan kapasitas produksi. Kegagalan biasanya terindikasi dari waste/ pemborosan yang muncul di sepanjang value stream. Terdapat indikasi defect yang tinggi melebihi 10% di sortir dan packaging process. Permasalahan utama adalah adanya waste/ pemborosan yang mengakibatkan penurunan kualitas dan kapasitas produksi. Paper ini akan mengidentifikasi waste yang terjadi di proses produksi, mencari akar penyebab terjadinya waste, dan membangun alternatif solusi perbaikan.  Diperlukan pemikiran kreatif untuk dapat menaikkan efisiensi sumber daya dan daya saing bisnis di pasar. Metoda yang dipakai untuk menyelesaikan permasalahan adalah Lean six-sigma. Konsep ini menelusuri permasalahan inefisiensi dengan mencari non value added activity dari munculnya waste di sepanjang value stream.  Kemunculan waste selanjutnya diidentifikasi lebih dalam dengan root cause analisys (RCA) dan failure mode and effects analysis (FMEA). Hasil akhir dari FMEA adalah risk priority number (RPN) yang menggambarkan prioritas atas mode resiko untuk dilakukan perbaikan. Dari hasil prioritas dirancang 3 alternatif perbaikan yaitu pelatihan operator, pembuatan SOP proses produksi, dan pelatihan karyawan quality control.   Dengan pendekatan net present value (NPV), maka diperoleh nilai NPV yang positif, artinya alternatif tersebut adalah layak untuk dijalankan. Alternatif ini meningkatkan nilai sigma dari sigma awal sebesar 2,80 menjadi 3,30. Kenaikan nilai sigma akan memberi indikasi adanya penurunan tingkat defect per million opportunities (DPMO), dan berakibat pada penurunan biaya sampai 20%.

scholarly journals Analisis Pengurangan Non-Value Added Activities dengan Metode Lean Six Sigma

2020 ◽  
Vol 2 (2) ◽  
pp. 63
Author(s):  
Iis Azelya ◽  
Gesit Thabrani
Keyword(s):  
Six Sigma ◽  
Value Added ◽  
Medical Personnel ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Contributing Factors ◽  
Value Stream ◽  
Outpatient Unit ◽  
Fishbone Diagram ◽  
Time Required

Purpose - This study was conducted with the intention to find out what is included as non-value added activity that is happened in patient’s flow and how to reduce it using lean six sigma method in outpatient department of regional public hospital of Kerinci M.H A Thalib.Methodology - This research uses lean six sigma method with analysis tools in the form of value stream mapping and fishbone diagrams in order to reduce the activities identified as non value added in the outpatient units of the M. H A Thalib general hospital in Kerinci Regency.Finding - The results of the study showed that the lead time required in the flow of patients in this outpatient unit is 7300.27 seconds with a percentage of Process Cycle Efficiency is only 12.22%, and contributing factors such as databases that are not used effectively, delays in medical personnel, lack of infrastructure, and so on. Keywords: Lean Six Sigma, Value Stream Mapping, Fishbone Diagram, DMAIC, Health Service, Reduce, Non-Value Added Activity

scholarly journals Integrasi Manajemen Perubahan pada Proyek Lean Six Sigma dalam Peningkatan Mutu dan Kinerja Perusahaan

2021 ◽  
Vol 10 (2) ◽  
pp. 113-120
Author(s):  
Ayesha Gilang Prahara ◽  
Catharina Badra Nawangpalupi
Keyword(s):  
Change Management ◽  
Six Sigma ◽  
Lead Time ◽  
Value Added ◽  
Production Quality ◽  
Lean Six Sigma ◽  
Small Enterprise ◽  
Improve Production Quality ◽  
High Level

PT X is a small enterprise producing various types of jute fabric products. As a traditional business, the company still largely rely on the handiness and crafting skills from their workers. Whilst the business competition increases, PT X requires to strengthen the business by improving product quality in an efficient way. Besides high level of defects, PT X has also non-value-added activities in their production resulting in high overtime hours of their workers. Although PT X considers the overtime is acceptable to achieve the production target, there is room for improvement to reduce the defects as well as to shorten the production lead time. This paper aims to tackle the inefficiency and quality of the company. Lean six sigma is proposed to improve the condition and change management is implemented to ensure the commitment and participation of all staff for the success of change. Hence, this paper proposes the combination of change management and lean six sigma to improve production quality, lead time and staff participation. Combining DMAIC methods with change management, a methodology called DMA(C)IC is used with the middle C is for change. The implementation of the integration between change management in lean six sigma has resulted in the reduced number of defects and shorter lead time and the awareness of the workers to improve their working behavior.

scholarly journals UPAYA PENINGKATAN KUALITAS PELAYANAN JALAN TOL SEMARANG-BAWEN DENGAN INTEGRASI METODE IMPORTANCE PERFORMANCE GAP ANALYSIS, LEAN, DAN SIX SIGMA

2017 ◽  
Vol 12 (2) ◽  
pp. 143
Author(s):  
Diana Puspita Sari ◽  
Ariani Putri Winanda ◽  
Arfan Bakhtiar ◽  
Dyah Ika Rinawati ◽  
Yusuf Widharto
Keyword(s):  
Service Quality ◽  
Six Sigma ◽  
Lead Time ◽  
Gap Analysis ◽  
Value Added ◽  
Value Stream Mapping ◽  
Performance Gap ◽  
Value Stream ◽  
Road Lighting

PT Trans Marga Jateng (TMJ) adalah sebuah perusahaan yang bergerak pada bidang jasa, yaitu mengelola jalan tol Semarang-Bawen. Berdasarkan survey pendahuluan yang dilakukan oleh PT TMJ menunjukkan bahwa kualitas pelayanan PT TMJ masih dianggap kurang memuaskan, sehingga perlu dilakukan penelitian mengenai peningkatan kualitas pelayanan. Kualitas pelayanan dapat diukur dari dua perspektif, yaitu perspektif internal dan perspektif eksternal. Perspektif eksternal dapat diukur dengan metode Importance Performance Gap Analysis (IPGA), sedangkan perspektif internal dapat diukur dengan metode  Lean dan Six Sigma. Sehingga, penelitian ini menggunakan integrasi metode IPGA,  Lean, dan Six Sigma dalam upaya meningkatkan kualitas pelayanan PT TMJ. Berdasarkan hasil penelitian, atribut kualitas pelayanan yang dianggap paling berpengaruh adalah penerangan jalan, kemulusan permukaan jalan, keselamatan mengemudi, dan penanganan kecelakaan. Usulan perbaikan yang diberikan untuk masing-masing atribut adalah penambahan lampu penerangan di titik-titik rawan kecelakaan, pemberian lapisan aspal pada bagian-bagian jalan yang bergelombang, memberikan perhatian khusus terhadap pelaksanaan indikator-indikator keselamatan mengemudi, dan perbaikan value stream pada penanganan kecelakaan. Value stream mapping hasil perbaikan menghasilkan waktu total lead time sebesar 150 menit dan persentase aktivitas value added sebesar 72,6%. AbstractPT Trans Marga Jateng (TMJ) is a company engaged in service sector, which is managing Semarang-Bawen toll road. The result of preliminary surveyconducted by PT TMJ showed that service quality of PT TMJ is still unsatisfactory, so it is necessary to do research on improving service quality. Service quality can be measured from two perspectives, i.e., internal perspective and external perspective. The external perspective can be measured with Importance Performance Gap Analysis (IPGA) method, while the internal perspective can be measured with Lean and Six Sigma method. Thus, this study will use the integration method of IPGA, lean, and six sigma in effort to improve service quality of PT TMJ. Based on the research result, service quality attributes considered the most influential is road lighting, road surface smoothness, driving safety, and accident handling. Suggested improvements for each attribute are road lighting installation at vulnerable points of accidents,asphalt layer installation on bumpy roads, paying particular attention to the implementation of safety driving indicator, and improving value stream of accident handling. Based on future state value stream mapping, total lead time is 150 minutes and value added activity percentage is 72,6%. 

Improving university facilities services using Lean Six Sigma: a case study

2015 ◽  
Vol 13 (1) ◽  
pp. 70-84 ◽  
Author(s):  
Mohsen F. Mohamed Isa ◽  
Mumtaz Usmen
Keyword(s):  
Six Sigma ◽  
Value Added ◽  
Lean Six Sigma ◽  
Content Type ◽  
General Improvement ◽  
Six Sigma Methodology ◽  
Construction Services ◽  
Design And Construction

Purpose – The purpose of this paper is to present a case study on the use of Lean Six Sigma principles and tools to study the improvement in design and construction services at a university. The quality of facilities services at universities has been criticized by users calling for improvement. Design/methodology/approach – Quality of facilities services at universities has been criticized by users calling for improvement. The purpose of this paper is to present a case study on using Lean Six Sigma principles and tools to study improving design and construction services at a university. Findings – It was found that non-value-added general improvement review form (GIRF) process steps involving revisions and rework for the design and construction result in time delays, cost increases and quality deficiencies and render cost estimates unreliable; these are unnecessary and should be minimized or eliminated. It was additionally noted that administrative reviews and approvals embedded in GIRF processes slow down work flow, leading to similar problems. Because such steps may be needed for institutional reasons precluding elimination, it was recommended that efforts be directed toward reducing their durations and costs. Overall, the Lean Six Sigma methodology proved to be successful for the intended purpose. Originality/value – Although universities are aware of their facilities services’ quality issues and have been addressing them, no published information is available on how to systematically evaluate and improve such services to increase customer satisfaction. This paper aims at filling this gap.

scholarly journals Study on Impact of Lean Six Sigma

2017 ◽  
Vol 3 (4) ◽  
pp. 508-513
Author(s):  
Koay Boon Hui ◽  
Shahryar Sorooshian
Keyword(s):  
Automotive Industry ◽  
Six Sigma ◽  
Lower Cost ◽  
Positive Impact ◽  
Lean Six Sigma ◽  
Data Driven ◽  
Global Competition ◽  
Statistical Tools ◽  
Value Stream

This paper purpose is to investigate the benefits of Lean Six Sigma to the Malaysian automotive industry. Lean is an approach that seeks to improve flow in the value stream and eliminate waste. It’s about doing things quickly. Six Sigma uses a powerful framework (DMAIC) and statistical tools to uncover root causes to understand and reduce variation. It’s about doing things right (defect free). As global competition continues to grow, the pressure to improve becomes more andmore intense. Thus, a combination of both Lean and Six Sigma is born. This method provides an over-arching improvement philosophy that incorporates powerful data-driven tools to solve problems and create rapid transformational improvement at lower cost. Thus, this paper also tries to examine how the Lean Six Sigma can contribute and brings a positive impact to the automotive industry in Malaysia.

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