Quality Improvement in Flexible Printed Circuit Board (FPCB) Using DMAIC Methodology: An Investigation in Semiconductor Industry

Continuous Process Improvement is methodology to solve the defect problem by increasing the effectiveness and efficiency of the business performances. DMAIC (Define-Measure-Analysis-Improve-Control) is a data improvement cycle designed for business process to find flaw or inefficiencies particularly resulting in defect or reject. This study was conducted at Company A and used DMAIC method to reduce the open defect for the circuit on the Flexible Printed Circuit Board (FPCB) from 0.6% to 0.3%. Part 13236 which has the highest open defect problem was chosen as the project improvement main focus. Imaging area was the main focus in this project because of its process forming the circuit. DMAIC methodology are initiated by problem identification through the past record of the open defect. The result observed for period of four months. After improvement, Part 13236 that have the highest defect decrease from 0.68% to 0.28% while the overall open defect decreases from 0.6% to 0.3%. The decline on product defect rate helps the company to improve the effectiveness and efficiency of business performances. It also results in cost saving which improves company’s profit margin in the long term.

Six Sigma Analysis as an Approach to Improve Quality of Corrugated Zinc Sheet Product

Every manufacturing company will strive to create the best quality products. This is also done by PT. CMSM, a steel company, is producing corrugated zinc products. In several production periods, the defective product values were still found that exceeded the tolerance limit value set at 0.5% in corrugated zinc products. These problems are, of course, very detrimental to the company, so it’s essential to control the quality of corrugated zinc products. This study aimed to determine the factors that cause product defects, propose plans to improve product quality, and provide managerial recommendations based on Six Sigma analysis. Data collection techniques are carried out through observation, interviews, and documentation. Based on the study results, it is known that DPO is 0.000885 and DPMO is 884.6028. At this time, the company is at the level of 4.64 sigma with CTQ (Critical to Quality) folded zinc sheet, cut size is not according to standard, thickness is not according to standard, uneven coating layer and perforated zinc sheet. Based on the analysis, five factors cause product defects: humans, machines, methods, materials, and the environment. To improve quality, the company should improve their quality control through 5W + 1H analysis, namely by providing training to employees, periodic machine maintenance and ensuring that the SOPs that have been made are implemented correctly and adequately. Keywords: six sigma, DMAIC, product defect, quality control, manufacturing

Product Recalls and Firm Reputation

Product recall data and information on stock price reactions to recalls are used to estimate the value of reputation in a model in which product quality is not contractible. A recall is the result of a product defect that signals low effort. The recall triggers a reduction in the firm’s product price and value, which then both rise steadily until its next defect occurs. We estimate that reputation accounts for 8.3 percent of firm value and that welfare is 26 percent of its first best level. A policy intervention that attains first best is a recall tax accompanied by a flow subsidy. (JEL D22, G32, H25, L25, L62, M31)

ANALISIS KECACATAN PRODUK TUNGKU KOMPOR DENGAN METODE STATISTICAL QUALITY CONTROL (SQC) DAN FAILURE MODE AND EFFECT ANALYSIS (FMEA) DI PT. ELANG JAGAD

Di era globalisasi kontemporer dengan berbagai persaingan, perusahaan dituntut untuk bersaing dengan segala resiko yang akan dihadapi. Cacat produksi yang minimal dan produk berkualitas adalah jaminan yang perlu dipenuhi perusahaan kepada konsumen. Oleh sebab itu, standard kualitas harus terus terjaga. Pengendalian kualitas, tujuan dan tahapan produksi, serta inovasi perlu diterapkan demi terselesaikannya masalah-masalah perusahaan. Salah satu upaya menjaga kualitas adalah dengan mengendalikan tingkat kerusakan produk (Product Defect). PT. Elang Jagad adalah perusahaan yang memproduksi tungku kompor di daerah Sidoarjo. Lingkup pemasarannya adalah daerah DKI Jakarta. Perusahaan yang bergerak di bidang ini rentan terjadi adanya kecacatan produk dan memiliki jumlah kecacatan yang pada bulan Januari – Desember 2020 sebesar 7.59%. Perusahaan menargetkan hanya ada 5% cacat dari keseluruhan total produksi. Masalah yang terjadi pada PT. Elang Jagad adalah proses produksinya yang mengakibatkan terjadinya cacat produk yang terdiri dari produk permukaan kasar, produk cuwil, enamel terkelupas dan produk permukaannya peyang/bergelombang/tidak rata karena terlalu lama di oven. Dalam hasil dan pembahasan ini, jumlah kecacatan yang paling sering terjadi adalah adalah Enamel Terkelupas (26.86%), Cuwil, (25.79%) dan Peyang Karena Terlalu Lama di Oven (23.39%). Dari hasil FMEA, nilai RPN terbesar terdapat pada kurangnya ketelitian di dalam mengerjakan dan SOP tidak dijalankan dengan baik sehingga berakibat cuwil sebesar 175. Usulan perbaikan adalah melakukan pengawasan lebih ketat dan briefing sebelum proses produksi dilakukan.

Usulan Perbaikan Kualitas Produk Labu Ukur Menggunakan Fault Tree Analysis (FTA) dan Failure Mode Effect Analysis (FMEA) di CV. X

Quality control is activities to be able to improve, maintain and improve the quality of the products produced. Because it controls the quality, it is very important to improve the quality of the products produced. Can improve the quality expected by all elements of the company can be obtained as expected. CV. X is a company established in the city of Bandung in 2003, Jakarta, Bogor and Central Java. The company is engaged in the production of various laboratory equipment such as erlenmayer, test tubes, drip pipettes, measuring flasks and measuring cups. The number of pumpkin production in 2016 was 2218, in 2017 as many as 2429 and in 2018 as many as 2871. Of the total production, the level of defect of pumpkin products measured an increase in 2016 of 3.5%, in 2017 amounted to 4.3% and in 2018 of 5.3%. The level of product defect exceeds the target or determined by the company for smoothness of 2%, it is necessary to improve the quality of product defects in the flask. Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA) can be used to analyze and provide solutions to improve the quality of defective products. Based on the processing and analysis of the data obtained on the type of defective form is not appropriate is the operator who is not careful with the value of RPN 120, the cause of screen printing defects that consider cleanliness, less careful, dirty work area, the user uses the operator to reverse the setting with the RPN value 144, causing damage back / broken ie operator settings change, less careful and less tidy work station with a value of RPN 240. Abstrak. Pengendalian kualitas merupakan aktivitas-aktivitas untuk dapat menjaga, mempertahankan dan dapat meningkatkan kualitas dari produk yang dihasilkan. Oleh karena hal tersebut pengendalian kualitas memiliki peranan sangat penting dalam terciptanya produk yang berkualitas. Sehingga tujuan yang diharapkan oleh seluruh elemen perusahaan dapat tercapai. CV. X merupakan perusahaan yang didirikan di Kota Bandung pada tahun 2003, berbasis usaha kecil menengah dengan pangsa pasar meliputi wilayah Bandung, Jakarta, Bogor dan Jawa Tengah. Perusahaan ini bergerak dalam produksi berbagai macam alat-alat laboratorium seperti erlenmayer, tabung reaksi, pipet tetes, labu ukur dan gelas ukur. Jumlah produksi labu ukur pada tahun 2016 adalah 2218, pada tahun 2017 sebanyak 2429 dan pada tahun 2018 sebanyak 2871 . Dari jumlah produksi tersebut, tingkat kecacatan produk labu ukur mengalami peningkatan yaitu pada tahun 2016 sebesar 3.5%, tahun 2017 sebesar 4,3% dan tahun 2018 sebesar 5,3%. Tingkat kecacatan produk sudah melewati ambang batas dari yang diharapkan perusahaan sebesar 2 % sehingga diperlukan upaya unuk mengatasi masalah kecacatan produk pada labu ukur . Fault Tree Analysis (FTA) dan Failure Mode and Effect Analysis (FMEA) dapat digunakan untuk menganalisis dan memberikan solusi terhadap perbaikan kualitas produk cacat. Hasil dari data yang telah diolah dan dianalisa, faktor penyebab kecacatan bentuk tidak sesuai yaitu operator kurang hati-hati dengan nilai RPN 120, penyebab cacat sablon yaitu perhatian terhadap kebersihan kurang, kurang hati-hati, stasiun kerja kotor, intensitas penggunaan alat tinggi, kurangnya pengawasan dan operator mengabaikan setting dengan nilai RPN 144, penyebab cacat retak/pecah yaitu operator mengabaikan aturan setting, kurang hati-hati dan stasiun kerja kurang rapi dengan nilai RPN 240.

A Forensic Engineering Approach to Documenting and Analyzing Domestic Plumbing Failures

Forensic engineering analysis of residential plumbing components can be a daunting task, particularly due to the manner in which they may be handled from the onset of a failure event. Usually, a water loss is discovered by a homeowner or tenant of a building where the source of the leak is easily determined. Remediation of a plumbing loss is likely to begin quickly and often compromises the investigation (i.e., the condition of the failed component changes, connections to the plumbing system are removed, etc.). Under most circumstances, the evidence is handled and collected by people without forensic training, such as the occupant or plumber, making spoliation a significant concern. This paper will discuss the scientific processes and evidence handling techniques utilized by forensic engineers to determine whether a product defect, installation defect, environmental condition, maintenance, or wear and tear were contributory factors to a plumbing loss.