REDUCING DIE CUT DEFECT USING DMAIC METHOD IN THE PACKAGING COMPANY

Abstract

PT. XYZ is a packaging company engaged in the manufacture of toy and food packaging. It is understood that the company has a problem that need to be improve. Because of this, defect packaging usually appears in every manufacturing, quality is one of the most critical things in manufacturing. An increase in defect product can cause losses for the company, therefore it is crucial to be handling that can be increase productivity. In order to avoid the alteration of defective product or even the accumulation of defect product. One of the techniques that can be used to reduce is the Six Sigma Method. In this research, the Six Sigma technique is used with DMAIC (Define, Measure, Analyze, Improve, and Control) method in studying the problems that occured. Based on the study conducted on three types of manufacturing defects, namely Die Cut method, Pond Handle method, and Joint Glue Method, each rejects in the Die Cut process has 48% or 5091 die cut defects, in the Pond Handle process is 29% or 3043 PH defects, and in the Joint Glue process is 23% or 2367 defects, with a total defects is 10501 pcs packaging defects. Also, found the abnormal machine and method factors in Die Cut, there is an abnormality in the machine caused by damaged spark plug that have not been replaced, and the method at the time of changeover carried out by Manpower is still not entirely using a good method. The result of this research, Total reject data has been improved by total percent is 67% more productive, 10501 total packaging defects reduced to 3421 packaging defects.