| Quality has been one of the most important aspects for companies to compete in this competitive era nowadays. That’s because the ignorance of this aspect, the company would not be success to build up the consumer satisfaction to use their products and services. Zebra Asaba Industries Co. Ltd., is a manufacturer company which focuses on production of writing instruments. One of the many problems on this company is defective products from their productions. D-M-A-I-C (Define-Measure-Analyze-Improve-Control) approach as a part of Lean Six Sigma method, can be used to minimize the number of those defective products. According to Product Quality (PQ) department, defective cases are mainly found on ballpoint Zebra Z-1 and ballpoint Zebra F-301. Based on calculation, the performance sigma are 4.16 (for ballpoint Z-1) and 4.67 (for ballpoint F-301). By using the Pareto analysis, the main defective found on ballpoint Z-1 are “imperfection printing result” and “rupture on plastic component”, while on ballpoint F-301 is “imperfection printing result”. By using fishbone diagram and FMEA, the main cause of those defects respectively are the lack of operators understanding of SOP, error of machine settings due to less-skilled operators, and inappropriate of ink viscosity. Based on these main causes, recommended actions were given. Hence resulting in improvement of the sigma performance to 4.17 (for ballpoint Z-1) and 4.72 (for ballpoint F-301). This improvement is not limited only on implementation, but also on control phase so that the defective cause would not happen in the future, and continues improvement has to be done to prevent other defective causes. Finally, the approach of D-M-A-I-C methodology in this Final Project is a Six Sigma project, which is only a portion of Six Sigma quality improvement program which have to be done continuously by this company. The final purpose is to reach the 6 sigma performance, correspond to the philosophy of this company, never ending improvement (Kaizen). |