REDUCING SHORT MOLD AND OVER RUBBER DEFECT IN SCREEN OIL FILTER PRODUCT USING DMAIC IN PT.X

Abstract

PT X is a rubber manufacturer that produces Screen Oil Filter for automotive industry. The company is having a problem regarding quality issues of Screen Oil Filter. The defective percentage in 2015 is always above the standard of the company goal and concerning in September 2015, Screen Oil Filter contributes IDR 18,168,558 of IDR 100,000,000 total company loss due to defects. Thus, DMAIC methodology is applied to reduce number of defects. The first step is defining problem opportunity and set the research goal. The second is measuring current quality, calculating defective cost and deciding short mold and over rubber as the main focus. The third step is analyzing the root cause of short mold and over rubber by using Fishbone Diagram. The next is conducting Design of Experimental as the improvement that will be implemented, after that controlling the output product by using Autonomous and First Time Yield. Then, measuring new quality and calculating defective cost. The last is comparing before and after improvement and calculating cost saving. Based on the result, quality level increases from 3 sigma becomes 4 sigma and the defective percentage reduces from 5.01% to 2.56% with cost saving is IDR 10,119,658.