IMPLEMENTASI LEAN SIX SIGMA DALAM MENGURANGI BREAKDOWN MAINTENANCE PADA SISTEM AUTOMATIC LENGTH CONTROL DI PT XYZ MENGGUNAKAN METODE DMADV

PT XYZ is a private company engaged in steel manufacturing, one of the products produced by this company is tire cord. This product is in the form of steel wire that serves to maintain the shape of the tire. The length of the wire is a very critical factor in quality, because one coil of wire that is not suitable length will cause a lot of scrap in consumers, namely the company that produces tires and of course this will cause customer complaints and customer dissatisfaction. Therefore, it is contained in the Automatic Length Control system to avoid the possibility of wire coils that are not suitable for delivery to customers. Every system must have weaknesses that lead to failure that causes maintenance breakdown. This study used the DMADV method to reduce breakdown maintenance on the Automatic Length Control system at PT XYZ. After going through all the stages using the DMADV method (Define, Measure, Analyze, Design, and Verify) a significant reduction in the number of breakdowns was obtained. Reduction of ALC-related breakdown maintenance by 88.1% or from 185 breakdowns to only 22 breakdowns. So that this flat pulley design was successful in reducing alc problems in henxing machines that produce tyre cord construction 3 +9 +15x0,23 +0.15 NT 6/12/18/5 SSZS

Download Full-text

Quality Control of the Steel Wire Rod Product by Integration Lean Six Sigma and Taguchi Method

MATEC Web of Conferences ◽

10.1051/matecconf/201821804013 ◽

2018 ◽

Vol 218 ◽

pp. 04013 ◽

Cited By ~ 1

Author(s):

Asep Ridwan ◽

Ratna Ekawati ◽

Ayu Novitasari

Keyword(s):

Taguchi Method ◽

Six Sigma ◽

Steel Wire ◽

Lean Six Sigma ◽

Second Step ◽

Effect Analysis ◽

Wire Rod ◽

Cause Of Failure ◽

Global Company ◽

Entry Guide

RMW Inc. is the global company in Indonesia. One of its product is the steel wire rod. This research aims to control the production process and improve the product quality. This research is using the integration between lean six sigma and taguchi method. The first step is to reduce the waste using lean six sigma method while the second step is to reduce the defect using taguchi method. Based on the identification of seven waste, the most dominant waste is the defect that is caused by there is no setting of the roll entry guide. The product has 11 CTQ (critical to quality) with the focus on laps defect, underfill defect, and overfill defect. Then, the cause of failure is identified using FMEA (failure mode effect analysis). The level of sigma capability is achieved at 4.54 with DPMO (defect per million opportunities) is 4006.55. The first improvement can reduce the time until 8.9 minutes. The second improvement sets the roll entry guide. The optimum factors for setting of the roll entry guide is A factor with 150 tonnages of wear level, C factor by 5 bar of cooling and D factor by 6 ml of lubrication.

Download Full-text

Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study

Quality Innovation Prosperity ◽

10.12776/qip.v23i3.1334 ◽

2019 ◽

Vol 23 (3) ◽

pp. 103 ◽

Cited By ~ 4

Author(s):

António M.H. Pereira ◽

Miguel R. Silva ◽

Mercedes A.G. Domingues ◽

José C. Sá

Keyword(s):

Continuous Improvement ◽

Six Sigma ◽

Critical Factor ◽

Lean Six Sigma ◽

Value Stream Mapping ◽

Future Research ◽

Competitive Advantages ◽

Pareto Analysis ◽

Study Results ◽

Six Sigma Approach

Purpose: The purpose of this article is to explore the optimization of internal process is assumed as a critical factor to be capable of answering to the moulds industries. Consequently, it has been considered essential to adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages. For that purpose, this work aims to apply LEAN principles and techniques to support mould design and manufacturing processes.Methodology/Approach: The methodology used was based on PDCA/DMAIC, with the following stages: Define, Measure, Analyze, Improve and Control. For each stages was taken some of Lean Six Sigma techniques, such as Continuous Improvement, Value Stream Mapping, Pareto analysis and Overall Equipment Effectiveness.Findings: This study results was revealed that there are many areas on the organizations in the Mould Industry, when they utilize otimizations tools obtain hugt successes. With the Pareto analysis was carried out to show that events that contributes the most to the stops. The results were: unavailability of the operator (16.4%), programming the machine (14.4%) and tool exchange (12.4%) In the case of this Mould Industry study was obtained for the CNC machines studies, with the implementation of Lean Six Sigma tools as obtained a improvement about 20% of global OEE.Research Limitation/implication: This research was revealed that there the moulds are Project unique and difficult to analyze. Moreover, this paper reports that the approach LEAN Six Sigma is very interesting for the continuous improvement of processes and profitability of moulds industry.Originality/Value of paper: This research highlight areas of future research using of quality management methods and Lean Six Sigma tools to analyse and optimize production in the moulds industry. Therefore this research It is considered to promote and adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages.

Download Full-text

A LEAN SIX SIGMA FRAMEWORK TO ENHANCE THE COMPETITIVENESS FOR SMES, EMPIRICAL EVIDENCE FROM

HUFLIT INTERNATIONAL CONFERENCE 2020 ON ENSURING A HIGH-QUALITY HUMAN RESOURCE IN THE MODERN AGE ◽

10.15625/vap.2020.00117 ◽

2020 ◽

Author(s):

Nguyễn Thị Xuân Lan ◽

Hoàng Đức Sinh

Keyword(s):

Empirical Evidence ◽

Six Sigma ◽

Lean Six Sigma

Download Full-text

EMPLOYEE ENGAGEMENT FOR HIGH FIRM PERFORMANCE: THE CASE OF LEAN SIX SIGMA AT A MALAYSIA TRADING COMPANY

e-Academia Journal ◽

10.24191/e-aj.v9i1.9518 ◽

2020 ◽

Vol 9 (1) ◽

Author(s):

Hadijah Iberahim ◽

Izmahariz Azman ◽

Mohd Haniff Shahri ◽

Nur Fara Ellyanie Abdul Hamid

Keyword(s):

Knowledge Sharing ◽

Employee Engagement ◽

Six Sigma ◽

Relevant Literature ◽

Lean Six Sigma ◽

Successful Implementation ◽

Management Support ◽

High Productivity ◽

Trading Company ◽

Goal Clarity

Lean Six Sigma (LSS) is a method that helps an organization to maximize profit and minimize cost. One of the essential factors for a successful LSS project is the availability of employees who are willing to engage. Employee engagement brings about a strong sense of belonging and high productivity. Consequently, engaged employees will work harder to achieve the mission of the organization. This paper discusses a case of LSS project with a low level of employee engagement. As a result, LSS was less likely helpful in sustaining company’s performance. The purpose of this study is to identify factors that contribute to employee engagement in LSS practices. Review of the relevant literature suggests four variables, which include goal clarity, management support and trust, knowledge sharing and transfer, and teamwork. The questionnaire survey applied census in collecting feedback from 80 respondents. Statistical analysis results indicate that goal clarity, management support, and trust are significant to employee engagement. However, knowledge sharing and transfer as well as teamwork are not substantial. It is recommended for the organization to give attention to all the four factors. This paper extended understandings on critical inputs to a successful implementation of LSS for sustainable company’s performance and growth. Keywords: Lean Six Sigma, Employee Engagement, Goal Clarity, Management Support and Trust, Teamwork, Knowledge Sharing.

Download Full-text