Reducing Production Defects in Box Products: A Six Sigma DMAIC Approach to Achieving Higher Process Capability

Abstract

The Six Sigma methodology has been adopted by industries as a business management tool to enhance operational capabilities and reduce defects in any process. This study aims to present a case study on the application of the Six Sigma DMAIC methodology with the objective of reducing the defect rate produced by PT. XYZ. This factory is a company engaged in handcraft-oriented manufacturing, with several machining processes involved. One of the products manufactured is the Gift Box, which has a higher defect rate compared to other products. The analysis identified five main types of defects: length discrepancy, dents, asymmetrical panels, height misalignment, and color inconsistency. The current process shows an average DPMO of 38,925 and a sigma capability of 3.25 out of 6, indicating a significant number of defects and that the goal of Zero Defects has not yet been achieved. The recommended improvements include worker training, time management, and SOP implementation that should align with the production process. Machine maintenance, calibration, and material monitoring are crucial to preventing product defects. These steps are expected to reduce defects, improve efficiency, and enhance process capability.

Keywords: Defect, Quality, Six Sigma, DMAIC.