REDUCING NUMBER OF MISSING STITCHES DEFECT IN ROOTING PROCESS AREA AT TOY MANUFACTURING COMPANY, CIKARANG

Abstract

PT. X is the biggest toy producer in the world wide. In order to produce a toy, PT. X has two main departments which are Industrial Engineering (IE) Primary and Secondary. IE secondary is dealing with creating tha main body of the toy while IE Secondary is dealing with creating the final look along with packaging of the toy. One of main process at IE secondary area is rooting process. Rooting process is a process to attach hair yarn to toy head. Neverthless, a major defect occur during the process since 2006 that is missing stitches. This issue cause PT. X loss IDR 105,782,933/Month and extra additional 11 days for rework during production time. Thus, 100% inspection, standarization, regular inspection and operator’s training are applied to overcome this issue through trial and experiments. As the result, PT. X is able to save IDR 8,922,933/month and no additional time needed for production process.