IMPLEMENTATION OF DMAIC TO REDUCE DEFECTIVE PRODUCT IN LINE A OF PT XYZ

Abstract

PT. XYZ as a food manufacturer is facing problems related to the amount of ppm defect for product RC in Line A. According to historical data in period of January 2018 until June 2018 the average of ppm defect for product RC is equal to 2,537.98. The main focus of this project is to reduce the ppm defect of product RC. This research conducted on May – September 2018. In this research, there are several objectives such as identifying the defects that has higher contribution to the PPM Defect for product RC in Line A, determining the improvement that can be used to reduce the most frequent defect in Line A by using DMAIC Methodology, determining the result after the improvement. In this research, there are several improvements that have been implemented in the packaging area, such as corrective action and preventive action in this case are kaizen by replacing the stoppers that has sharp edges and in the improper position, by replacing the conveyor belt on the declining conveyor, and by installing divider on the upper conveyor. After all of the improvements have been implemented, the number of ppm defect reduced to 709.79 in October 2018. Compared to January 2018 with 2,946.05, the number of ppm defect in October 2018 decreased by 75.91% of the ppm defect on January 2018, although the total production on October 2018 is larger than January 2018.