| PT. Federal karyatama is one of the manufacturing company engaged in the oil & energy. Companies engaged in this field should certainly be unbelievably concerned about the quality of its products. Based on the research conducted, often found there is a discrepancy in the quality of the final product. Discrepancy is found in the quality of sealing and capping process that is part of a line of lubricant packaging. The resulting defect is often reached large proportions. It interferes with the productivity and efficiency of production. The issue sought alternative solutions to the Six Sigma method. In this method of research is done by using the DMAIC phases Define - Measure - Analyze - Improve - Control, which included a lot of use of the methods and tools of quality control. Define phase aims to identify the relationship between the elements - SIPOC diagram elements with the production, manufacturing process flow diagram for identification, problem statement, and the determination of Critical to Quality. Measure phase begins with the calculation of map control, all the values are outside the control limit removed, and subsequently calculate process capability, which gained Cp and Cpk for each product. DPMO and sigma level obtained from the performance measurement baseline is equal to 213.01 and 5.02 for products of the category AHM MPX reject cap, 139.12 and 5.13 of the reject category bottles, while of FO Flick products amounted to 368.80 and 4.88 to reject stamp, 81.47 and 5.27 to reject the bottle. The entire calculation results are analyzed on the Analyze phase, making fishbone diagrams, and FMEA. The root cause of any defect is not stable machine, errors in the calculation of machine settings, less skilled, lack of supervision, lack of inspection, as well as material that has been too long. Potential failure mode FMEA is of quality material, RPN value for this mode is at 343. Repairs performed experiments using 5W-2H and improve performance of an experiment at this stage. Implementation of the experiment were compared using two proportions test to compare conditions before and after the implementation of improvements. Based on the research results are a significant influence on the decreasing number of defects. Control proposals including preventive maintenance to keep the stability of the machine and prevent defects. |