REDUCING SCRAP IN COMPRESSION PANCAKE PRESS INSPECTION USING DMAIC AT PLASTIC MANUFACTURING

Abstract

PT. NPC is a company that produces plastic resins and color compounds as its main products. There is an issue in the company where there is significant waste in the QC department of PT. NPC on the use of finished products that will be used as a sample of quality tests. The scrap contained in this research where the product cannot be reconditioned or sold, but the scrap will be turned into junk and will be disposed of. The waste of quality samples can affect the finances of the company because the Quality sample used has the same price value as the product that will be marketed by the company. Based on historical data contained in the QC department. PT. NPC produces more than 1000 kg of scrap product every month, which must be disposed of by the company. This research finds the root causes of scrap produced during the quality test process. The method used in this research is DMAIC method and several tools to find the root cause of the problem. From the analysis, it was found that the root causes are coming from several aspects, which are improper sample measurement, improperly used sample, machine cleanness, and improper machine setting. the result of the improvement can reduce the scrap produced in the QC department by about 43% and the impact of the improvement after implementation can reduce the financial cost of IDR 14,497,973 to the company.