Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Authors

  • Indra Setiawan Department of Industrial Engineering, Mercu Buana University
  • Setiawan Setiawan Department of Industrial Engineering, Mercu Buana University

DOI:

https://doi.org/10.30656/jsmi.v4i2.2775

Keywords:

Quality, Defect, Six sigma, DMAIC, Roof panel

Abstract

Product quality has now become one of the main factors that every company must have to compete globally. One way is to reduce the number of defective products in the production process. This method is a continuous improvement effort made by PT Toyota Motor Manu­fac­turing Indonesia and companies engaged in the automotive sector that produces cars. One of the processes is packing roof panels whose output will be sent to importing countries where the number of re­quests per month is relatively high but still has a high defect rate. Based on production data and defect data for the January-February 2019 period, roof panel packaging production has a 1% -3% defect rate. This company must reduce the defect rate to achieve the com­pany target of zero defects. This study aims to improve the quality of the packaging process by minimizing the number of defective products. This study uses the Six Sigma method with DMAIC phases. This method has several phases, namely, Define, Measure, Analysis, Improvement, and Control. Corrective action to reduce product defects based on 5W + 1H is to formulate a repair plan at the upgrade phase, namely by making SOPs spraying anti-rust and supervising operators who produce roof panel packaging. The improvement results reduced the DPMO value from 33,500 units to 2,050 units and increased the sigma level from 3.33 to 4.37. The DMAIC phase effectively controls and improves product quality levels in the automotive industry.

Downloads

Download data is not yet available.

References

A. Banawi and M. M. Bilec, “A framework to improve construction processes: Integrating Lean, Green and Six Sigma,†Int. J. Constr. Manag., vol. 14, no. 1, pp. 45–55, Jan. 2014, doi: 10.1080/15623599.2013.875266.

A. Yadav and V. K. Sukhwani, “Quality improvement by using six sigma DMAIC in an industry,†Int. J. Curr. Eng. Technol., vol. 6, no. 6, pp. 41–46, 2016, Available: https://inpressco.com/wp-content/uploads/2016/10/Paper1041-46.pdf.

A. Roy, E. Henrik, and T. Håkan, “Similarities and differences between TQM, six sigma and lean,†TQM Mag., vol. 18, no. 3, pp. 282–296, Jan. 2006, doi: 10.1108/09544780610660004.

V. Gaspersz, Lean Six Sigma. Jakarta: Gramedia Pustaka Utama, 2007. Available: https://books.google.co.id/books?id=-APoYfWmr7AC.

P. S. Pande, R. P. Neuman, and R. R. Cavanagh, The Six Sigma Way: How GE, Motorola, and Other Top Companies are Honing Their Performance. McGraw-Hill Education, 2000. Available: https://books.google.co.id/books?id=ybOuvzvcqTAC.

J. E. Brady and T. T. Allen, “Six Sigma Literature: A Review and Agenda for Future Research,†Qual. Reliab. Eng. Int., vol. 22, no. 3, pp. 335–367, Apr. 2006, doi: 10.1002/qre.769.

K. Sameer, S. Erika, and T. Douglas, “Improved service system design using Six Sigma DMAIC for a major US consumer electronics and appliance retailer,†Int. J. Retail Distrib. Manag., vol. 36, no. 12, pp. 970–994, Jan. 2008, doi: 10.1108/09590550810919388.

A. V., A. Jiju, and D. Alex, “Observation: a Lean tool for improving the effectiveness of Lean Six Sigma,†TQM J., vol. 24, no. 3, pp. 275–287, Jan. 2012, doi: 10.1108/17542731211226781.

S. Vikas and V. S., “Deploying Lean Six Sigma framework in an automotive component manufacturing organization,†Int. J. Lean Six Sigma, vol. 7, no. 3, pp. 267–293, Jan. 2016, doi: 10.1108/IJLSS-06-2015-0023.

E. Megawati, P. A. Wicaksono, and D. Nurkertamanda, “Reducing defect in furniture industry using a lean six sigma approach,†in AIP Conference Proceedings, 2020, vol. 2217, no. 1, p. 030180, doi: 10.1063/5.0004282.

M. C. Prieto-avalos, C. R. Navarro-gonzalez, A. Gonzalez-angeles, and S. V. Medina-leon, “Reduction Waste by Combining Lean Manufacturing and Six Sigma in an Electronics Industry,†Res. J. Appl. Sci. Eng. Technol., vol. 8, no. 13, pp. 1558–1562, Oct. 2014, doi: 10.19026/rjaset.8.1133.

C. L. Jung, “Implementing Six Sigma within Kaizen events, the experience of AIDC in Taiwan,†TQM J., vol. 30, no. 1, pp. 43–53, Jan. 2018, doi: 10.1108/TQM-02-2017-0017.

E. V Gijo, A. Jiju, and S. M. Vijaya, “Application of Lean Six Sigma in IT support services – a case study,†TQM J., vol. 31, no. 3, pp. 417–435, Jan. 2019, doi: 10.1108/TQM-11-2018-0168.

G. E.V. and S. Ashok, “Application of Six Sigma to improve the quality of the road for wind turbine installation,†TQM J., vol. 25, no. 3, pp. 244–258, Jan. 2013, doi: 10.1108/17542731311307438.

K. Srinivasan, S. Muthu, S. R. Devadasan, and C. Sugumaran, “Enhancement of sigma level in the manufacturing of furnace nozzle through DMAIC approach of Six Sigma: a case study,†Prod. Plan. Control, vol. 27, no. 10, pp. 810–822, Jul. 2016, doi: 10.1080/09537287.2016.1143130.

P. Jirasukprasert, J. Arturo Garza-Reyes, V. Kumar, and M. K. Lim, “A Six Sigma and DMAIC application for the reduction of defects in a rubber gloves manufacturing process,†Int. J. Lean Six Sigma, vol. 5, no. 1, pp. 2–21, 2014, doi: 10.1108/IJLSS-03-2013-0020.

N. Nelfiyanti, A. M. Rani, and A. Fauzi, “Implementasi Six Sigma untuk Perbaikan Kualitas Produk Kiwi Paste Berdasarkan Keluhan Pelanggan,†J. Sist. dan Manaj. Ind., vol. 2, no. 1, pp. 41–50, Jul. 2018, doi: 10.30656/jsmi.v2i1.609.

J. P. Costa, I. S. Lopes, and J. P. Brito, “Six Sigma application for quality improvement of the pin insertion process,†Procedia Manuf., vol. 38, pp. 1592–1599, 2019, doi: 10.1016/j.promfg.2020.01.126.

H. Saeid, Z. S. Mojib, and M. R. Jafri, “Application of Six Sigma DMAIC methodology in plain yogurt production process,†Int. J. Lean Six Sigma, vol. 9, no. 4, pp. 562–578, Jan. 2018, doi: 10.1108/IJLSS-11-2016-0069.

V. Iwan, H. T. Kim, S. Nurhadi, A. N. Indah, and P. F. Mega, “Halal six sigma framework for defects reduction,†Journal of Islamic Marketing, vol. ahead-of-p, no. ahead-of-print. Jan. 01, 2020, doi: 10.1108/JIMA-11-2019-0232.

A. Subhan, “Optimalisasi Proses Produksi Celana Panjang Melalui Pendekatan Six Sigma,†J. Sist. dan Manaj. Ind., vol. 2, no. 1, pp. 23–32, Jul. 2018, doi: 10.30656/jsmi.v2i1.559.

S. Mahendru and B. Singh, “DMAIC-Measuring the PVC Pipe Manufacturing Process,†Am. J. Econ. Financ. Manag., vol. 1, no. 4, pp. 293–303, 2015. Available: http://files.aiscience.org/journal/article/pdf/70220003.pdf.

R. Sharma, P. Gupta, and V. Saini, “Six sigma DMAIC Methodology Implementation in Automobile industry: A case study,†J. Manuf. Eng., vol. 13, no. 1, pp. 42–50, 2018. Available: http://smenec.org/wp-content/uploads/Mar2018-v13-i1-Raman.pdf.

S. Krishna Priya, V. Jayakumar, and S. Suresh Kumar, “Defect analysis and lean six sigma implementation experience in an automotive assembly line,†Mater. Today Proc., vol. 22, pp. 948–958, 2020, doi: 10.1016/j.matpr.2019.11.139.

E. V. Gijo and J. Scaria, “Reducing rejection and rework by application of Six Sigma methodology in manufacturing process,†Int. J. Six Sigma Compet. Advant., vol. 6, no. 1/2, pp. 77–90, 2010, doi: 10.1504/IJSSCA.2010.034857.

E. V Gijo and T. S. Rao, “Six Sigma implementation – Hurdles and more hurdles,†Total Qual. Manag. Bus. Excell., vol. 16, no. 6, pp. 721–725, Aug. 2005, doi: 10.1080/14783360500077542.

M. Kaushik, G. Chauhan, K. Mathiyazhagan, R. Ojha, and M. Kumar, “Reducing rejections using Six Sigma: a case from Indian automobile component manufacturing industry,†Int. J. Serv. Oper. Manag., vol. 33, no. 1, pp. 69–86, 2019, doi: 10.1504/IJSOM.2019.099655.

Downloads

Published

2020-12-29

How to Cite

[1]
I. . Setiawan and S. Setiawan, “Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study”, j. sist. manaj. ind., vol. 4, no. 2, pp. 108–116, Dec. 2020.

Issue

Vol. 4 No. 2 (2020)

Section

Research Article

License

All articles in Jurnal Sistem dan Manajemen Industri can be disseminated provided they include the identity of the article and the source of the article Jurnal Sistem dan Manajemen Industri. The publisher is not responsible for the contents of the article. The content of the article is the sole responsibility of the author

Creative Commons License

Jurnal Sistem dan Manajemen Industri is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.

Crossref
Scopus
Google Scholar
Europe PMC