REDUCING MOISTURE DEFECTS OF PRODUCT NYLON IN PT. NPS BY IMPLEMENTING DMAIC METHOD OF LEAN SIX SIGMA

Abstract

The research is done in PT. NPS one of the plastic coloring compound, the issues in the company are the finished product has a high level of moisture content which mean the product contains more water more than it tolerates it affect to the molding and result, another problem is the high amount of defect products in warehouse becoming block assets. The research has purpose to find the root causes of Moisture defects from product nylon, reducing the root causes by implementing improvement and finding treatment action to eliminate the existing defects in the warehouse, so it could be sell and gives profit to the company. The methods are DMAIC from Lean Six Sigma Methodology and several tools to finding the root causes. From the analysis, it is found that the root causes are coming from several aspects which are no adjustment training, lack of monitoring, no double-checking, and gap in packaging seal. The results are increasing the average Sigma level from 4.39 to 5.64. The DPMO improves from 1,751.55 to 42.31, reduce the DPMO by 98%. The financial aspect, the improvement bring profit IDR 1,087,099,800 to the company. For the treatment, the best alternative is reworked instead of dry-up.