PT. Bumimulia Indah Lestari is a plastic packaging manufacturer company in Indonesia. It produces plastic bottles for household cleaning products, pharmacies, cosmetics, foods and beverages and also lubricates. High quality is a requirement for PT. Bumimulia Indah Lestari to stay competitive and profitable in more complex competition. One of the ways to increase profitability internally is eliminating or at least minimizing cost paid by company due to poor quality. The bottles for household cleaning products have the highest amount of production with 1%-5% of defects per-month. This project has identified that the blow molding process have the highest percentage of defects and in that process, Sunclin?s bottles causing Rp.4.303.260,00 in average of cost of poor quality in each month. The goal of this research is to analyze the defects process with Six Sigma method.
Six Sigma is a method directly searching and targeting the root of problems. The method used in this Six Sigma project is Define-Measure-Analyze-Improve-Control. The project started with Define phase, to define product and process that need improvement, which is Sunclin?s bottle in blow-molding process. Later, we setup a project and goal statement which is decrease cost poor quality COPQ. In Measure phase, we need to find the key characteristics or well knows as Critical To Quality (CTQ) and measure the company?s sigma capability. Following the measurement of baseline performance, in the Analyze phase we use Failure Modes and Effect Analysis (FMEA) to analyze the root causes of the problems which has cause high defect rate. In the Improve phase, we use Taguchi Method to move the process to approach an ideal target, zero defects. Next, in the Control phase, we suggest a Control Plan sheet to help the company control it process.
The tabulation result shows the company?s present sigma capability of 3.93 with 7434 defects per million opportunities (DPMO). As we get the information about its root causes and proper and suitable solution with Taguchi Method, we conclude that the water/cooler temperature should be set to 15 degree Celsius, which later be validate. After the implementation, the sigma capability increases to 4.11 while the DPMO decrease to as low as 4444 DPMO and COPQ decrease to only Rp. 2.630.472,00. |