DEFECTS ELIMINATION IN CASTING DEPARTMENT OF PT. KMI USING DMAIC IMPLEMENTATION

Abstract

Quality is an important aspect that has to be prioritized by company because quality is the standard expectations of the product that offer by the company and agreed by customer to satisfy the customer’s expectation. However, to this day many company still facing the similar issue where the quantity of the nonconformity product is higher than targeted standard. PT. KMI, a manufacturing company that produce ceramic products is one of the company that face the issue, the highest defect is coming from casting department in the production of 2P product has more than 10% from the total output. Most of the 2P products are having issue in the appearance which cannot satisfy the customer’s requirement. The aspects that affected by the high amount of defect are quality, delivery and output, cost, and rework. This research will focus on implementing DMAIC to reduce the number of the defects and maintain the number of defect is lower than the standard, conducting root causes analysis with fishbone diagram to identify the potential causes and implementing corrective and preventive action to control to reach the zero defect. From the analysis there are 27 corrective and preventive action identified and able to be implemented, the result is reducing 10% of the appearance defect from the production process.