IMPLEMENTATION OF SIX SIGMA IN INJECTION PROCESS STAGE TO REDUCE BURRY DEFECT OF GEAR OIL PUMP PRODUCT IN PT. ABC

Abstract

In this modern manufacturing era, each manufacture based company would tried their best to provide their loyal customers with a product that has added value. PT. ABC as a leading multinational company in polymer product manufacturing, with a focus in the motorcycle parts manufacture. A good six sigma implementation demands a continuous improvements, with aiming in the DPMO value to be as minimum as possible, so that a quality target could be achieved and could be considered zero defect, also to be assessed later along with DMAIC (Define, Measure, Analyze, Improve, Control). The desirable results have been obtained after an improvements phase, with a sigma value of 3.4 in the period of January to March 2018, then achieved 3.9 sigma in the period of April to June 2018, with a focus in minimizing burry defects. Those boosts of sigma value were also caused by defect occurrences that were decreased for 75%. Indeed, the effect of the improvements implementation could prevent the further loss suffered by the company for IDR 135,023,000 loss in pre-improvement period into a decrease of only IDR 33,883,000 loss in after-improvement period.