REDUCING DEFECT RATE BY APPLYING DMAIC METHODOLOGY IN PRODUCT PACKAGING AT PT.X

Abstract

As a packaging manufacturer, PT. X is experiencing issues with the quantity of PPM defect for product GTN43-JA10 in the production flow process, particularly during the printing stage and attaching J-Hook to the packaging. The researcher conducted this research from Nov – to January. The objective that covers this research is identifying the defects that have a higher contribution to the PPM Defect for product GTN43-JA10, whereas the results are Non-standard colour and J-Hook run. Therefore, this research covers the development of new standard operation to perform an improvement that the company can use to reduce the most frequent defect in Printing and the attachment of J-Hook using DMAIC Methodology. The improvement include, substituting the divider in the J-Hook machine with a new one designed by the IE team and a development of a new standard or "Acuan Kerja" for the materials utilized and the functioning of the KBA printing machine. In January 2022, after the improvements, the number of PPM defects had decreased to 152.09 which have a sigma level of 3.61 from 1275 PPM with a sigma level of 3.02. The number of PPM decreased by 88% and increase by 0.59 sigma level after the improvement has been implemented.