IMPLEMENTATION OF DMAIC METHODS TO REDUCE PEELED OFF DEFECT IN ESP AREA AT TOY MANUFACTURING COMPANY, INDONESIA

Abstract

Toy Manufacturing Company, Indonesia has a project to reduce number of peeled off defect in Electrostatic Painting area and increase the process capability in pre-treatment process. Peeled off defect contributes 40% from total defect in Electrostatic painting and become scrap that costs IDR 77,992,673. This defect occurred because of the improper cleaning process in pre-treatment area. Free alkali and acidity level in Parco Spray, Hot Water Rinse 1, and Hot Water Rinse 2 are the critical parameter to be measured. This research implements Lean Six Sigma approach through DMAIC methodology. Several improvements are done which is install auto-dosing and auto-stirrer in parco spray, auto-drain by sensor pH in Hot Water Rinse 2, add 20 micron filter mesh, modify paint stirrer, and scheduled pH checking in Hot Water Rinse. The Cp and Cpk indexes of Parco, HWR 1, and HWR 2 have increased become higher than 1.00 which categorized as capable process. Then, number of clogged nozzle per week decreased by 66%. By that, peeled of defect has decreased by 72% in quarter 2 and quarter 3 2020. By this research, Toy Manufacturing has total cost savings up to IDR 90,482,642.