Penerapan Metode Six Sigma dengan Pendekatan DMAIC untuk Mengurangi Jumlah Kecacatan Produk Housing Cover MCB pada PT XYZ

Abstract

PT XYZ is engaged in the production of electronic and automotive spare parts through injection molding process. One of the products produced is the MCB Housing Cover. The problem faced by the company is the existence of product defects with an average percentage of defects of 5.85% where this exceeds the company standard of 2%. The purpose of this research is to identify the source of quality problems and analyze product quality control to reduce product defects through the Six Sigma approach with the integration of FMEA methods to strengthen the identification and prioritization of potential failures and TRIZ to produce more creative and objective solutions. In the production process, 3 types of defects were found, where the two main types of defects (Short Shot and Flash) cumulatively accounted for 79.38% of the total defects. Based on the results of the processed data, a DPMO value of 19,502.26 and a Six Sigma Level of 3.56 were obtained. Through fishbone diagram analysis and FMEA, it is known that the main causes of short shots come from machine factors (RPN 432) and methods (RPN 336). For flash defects, method (RPN 384) and human factors (RPN 294) are the dominant causes. Proposed improvements for human factors include reducing factors that require high attention from operators. For the machine factor, improvements were made by gradually adjusting the injection pressure. For the method factor, it is proposed to make a written SOP posted in the production area that contains proposed improvements with 40 Inventive Principle TRIZ including the principle of periodic action, namely adjusting the injection speed repeatedly so that the plastic flow is more stable, as well as parameter changes to reduce mold temperature and increase cooling efficiency