Kreator Volume 12.
Number 2, 2023 pp.
P-ISSN: 2354-9505 E-ISSN : 2548-9542
Open Access: https://doi.
org/10.
46961/kreator.
Analysis of the Implementation of the PDCA Method to Minimize Delamination Complaints in Oilpacks Products at PT XYZ Nazwa Febriyan1.
Arrahmah Aprilia2.
Alfred Satyahadi2 1,2 Teknologi Rekayasa Pengemasan.
Politeknik Negeri Media Kreatif.
Jakarta.
Indonesia
ABSTRAK
ARTICLE INFO
Article history:
Received July 7, 2025 Revised December 12, 2025 Accepted December 31, 2025 Available online December 31.
Kata Kunci:
Metode PDCA.
Perbaikan berkelanjutan, quality control, delamination, manufacturing Keywords:
PDCA Method.
Continuous Improvement.
Quality Control.
Delamination.
Manufacturing Industry This is an open access article under the CC BY-SA license.
Copyright A 2023 by Author.
Published by Politeknik Negeri Media Kreatif Penelitian ini bertujuan untuk menganalisis efektivitas penerapan metode PDCA (Plan-Do-Check-Ac.
dalam menurunkan jumlah keluhan delaminasi pada produk Oilpack di PT XYZ.
Delaminasi merupakan salah satu jenis cacat produk yang berdampak langsung terhadap mutu, daya tahan kemasan, serta tingkat kepuasan Jika tidak ditangani secara sistematis, masalah ini dapat menurunkan citra perusahaan dan meningkatkan biaya produksi akibat rework maupun klaim pelanggan.
Oleh karena itu, diperlukan pendekatan perbaikan berkelanjutan yang terstruktur dan terukur.
Melalui tahapan PDCA, penelitian ini berhasil mengidentifikasi penyebab utama terjadinya delaminasi, yaitu kualitas bahan baku yang tidak konsisten, ketidaksesuaian parameter proses produksi, serta lemahnya pengawasan pada tahapan tertentu.
Pada tahap Plan dilakukan analisis akar masalah menggunakan data historis keluhan pelanggan.
Tahap Do mencakup implementasi tindakan korektif berupa peningkatan pengendalian mutu bahan baku, penguatan kontrol proses produksi, serta pelatihan karyawan terkait standar operasional prosedur (SOP).
Tahap Check dilakukan dengan mengevaluasi dan membandingkan data keluhan sebelum dan sesudah perbaikan, sedangkan tahap Act menetapkan standar kerja baru sebagai langkah pencegahan berulang.
Hasil penelitian menunjukkan penurunan keluhan dari 16% menjadi rata-rata 5%.
Jumlah keluhan mingguan juga menurun dari 10 menjadi 6 kasus .
enurunan 40%), sehingga membuktikan bahwa metode PDCA efektif dalam meningkatkan pengendalian mutu dan efisiensi proses ABSTRACT This study aims to analyze the effectiveness of implementing the PDCA (Plan-Do-Check-Ac.
method in reducing the number of delamination complaints in Oilpack products at PT XYZ.
This study aims to analyze the effectiveness of implementing the PDCA (Plan-Do-Check-Ac.
method in reducing the number of delamination complaints in Oilpack products at PT XYZ.
Delamination is a type of product defect that directly affects product quality, packaging durability, and customer satisfaction.
If not addressed systematically, this issue can reduce the companyAos reputation and increase production costs due to rework and customer claims.
Therefore, a structured and measurable continuous improvement approach is required.
Through the PDCA stages, this study identified the main causes of delamination, including inconsistent raw material quality, nonconformities in production process parameters, and weak monitoring at certain stages of production.
In the Plan stage, root cause analysis was conducted using historical customer complaint data.
The Do stage involved implementing corrective actions such as improving raw material quality control, strengthening production process control, and providing employee training related to standard operating procedures (SOP).
The Check stage evaluated the results by comparing complaint data before and after the improvement process, while the Act stage established new work standards to prevent similar issues from recurring.
The results show that complaints decreased from 16% to an average of 5%.
*Corresponding author E-mail addresses: arrahmah_aprilia@polimedia.
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Weekly complaints also declined from 10 to 6 cases, representing a 40% reduction, indicating that the PDCA method is effective in improving quality control and production process efficiency.
INTRODUCTION
Under actual field conditions, products that do not meet established quality standards are still found.
Some of these products even pass internal quality control processes and are delivered to customers, resulting in complaints that require serious Therefore, a comprehensive investigation is necessary to identify the root causes of the problem .
hy it happene.
and to determine why the defective products were able to pass the quality control process .
hy it passe.
One concrete example of quality issues at PT XYZ is the delamination defect in oilpack products.
This defect not only affects the packaging appearance but also reduces the perceived product quality and potentially compromises product safety during its shelf life.
To address this issue, the company has implemented the PICA (Problem Identification and Corrective Actio.
system as a systematic approach to quality improvement.
However, in practice.
PICA has not consistently provided long-term solutions.
This may be due to insufficient root cause analysis, limitations in the execution of corrective actions, and weak monitoring of implementation results in the field.
As a result, several issues have reoccurred in the form of repeated complaints, including persistent delamination despite corrective measures, indicating weaknesses in the quality control system and the effectiveness of PICA.
Therefore, a comprehensive evaluation of the PICA process is required in terms of the accuracy of problem identification, the appropriateness of corrective actions, and the reliability of the prevention system.
Delamination is a common issue in flexible packaging for oilpack products, caused by weak bonding between plastic film layers, leading to packaging leakage and potential financial losses.
Based on complaint data from Plant 1 of PT XYZ in 2024, delamination was the primary cause of complaints during the JuneAeSeptember 2024 period, highlighting the urgency of addressing this issue.
In this context, the implementation of the PDCA (PlanDo-Check-Ac.
method becomes highly relevant, as it integrates root cause analysis, risk prioritization, and corrective action planning.
Previous research has shown that the application of PDCA reduced product defects from 0.
085 to 0.
030 DPU, meeting company standards (Utami & Djamal, 2.
However, previous studies have not specifically focused on delamination issues.
For instance.
Nugroho & Nugroho .
analyzed the reduction of reject rates without deeply identifying the root causes of delamination.
Therefore, this study focuses on implementing PDCA to address oilpack product delamination using an integrated and specific approach aligned with the characteristics and challenges at PT Indofood CBP Sukses Makmur.
presenting empirical data and evidence-based recommendations, this study is expected to contribute to continuous improvement within the company and serve as a reference for other packaging industries in implementing more effective quality control strategies.
Based on the literature review, no prior research has specifically implemented PDCA to address delamination as a primary priority in quality control.
Previous studies have generally discussed defect rates in aggregate without prioritization based on defect dominance.
This gap highlights the need for a more focused and specific study on delamination as a major contributor to production defects.
Therefore, this research offers a novel contribution by positioning delamination as the main focus of analysis and integrating the PDCA stages to develop more measurable and effective improvement strategies.
The method used is PDCA (Plan.
Do.
Check.
Ac.
, involving direct observation and interviews with operators.
According to Taufik .
, the PDCA (Plan-Do-Check-Ac.
Nazwa Febriyan/ Analysis of the Implementation of the PDCA Method to Minimize Delamination Complaints in Oilpacks Products at PT XYZ Kreator Vol.
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method is a continuous improvement cycle that is future-oriented, flexible, logical, and structured to realize the planned objectives.
Figure 1.
Frequency of Customer Complaints.
JuneAeSeptember 2024 The data analysis was carried out using 7 quality tools.
In the Plan stage, the author used a cause-and-effect diagram (Fishbone diagra.
In the Do stage, the 5W 1H approach was used to create improvement proposals.
In the Check stage, changes were evaluated by comparing data before and after analysis using a Control Chart.
Before implementing PDCA, the average number of complaints was recorded at 10 cases per After three months of implementation, this number decreased to 6 cases per week, representing a 40% reduction.
This data supports the effectiveness of the PDCA method in controlling and improving service quality.
RESULTS AND DISCUSSION
Plan The following is the pass reject data from June to September 2024.
June recorded the highest number of defects, while the subsequent months showed a decline, remaining within the UCL and LCL limits.
Figure 2.
Pass Reject JuneAeSeptember 2024 Kreator P-ISSN: 2354-9505 E-ISSN : 2548-9542 Kreator Vol.
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Table 1.
Statistical Quality Control Pass Reject 2024 No.
Month June 2024 July 2024 August 2024 September Production .
Defect
Proportion UCL
LCL
Do (Implementatio.
Ae 5W 1H Factor What Lack of Man Why Who Where When - Operator did not follow standard - Insufficient During control over ozone Operator Machine - Operators did not clean the extruder hood regularly How Briefing regarding ozone supply and periodic extruder hood cleaning - Poor glue - Rubber roll pressure low - Etching cylinder - Monitor glue pump circulation and report blockage to section head for immediate During - Ensure rubber roll Operator Machine process pressure meets reject rolls with dents - Replace or rechrome worn etching - Applicator - Create ozone monitoring checklist During Operator Machine - Develop OPL (One Point Lesso.
for cleaning applicator Machine Insufficient glue supply Supply Ozone Ozone Hood Extruder - Review WI for hood Dirty extruder - Parafin deposits During cleaning and create Operator Machine from resin vapor process routine cleaning Method No standard - No control over - Establish standard During ozone applicator Operator Machine procedures and and hood cleaning cleaning schedules Non-standard - Machine not Parameter parameters calibrated Material Incorrect glue/resin - Wrong - Notify technical During team for calibration Operator Machine process and schedule regular machine checks Operator Machine - Ensure correct glue During mixing and proper Nazwa Febriyan/ Analysis of the Implementation of the PDCA Method to Minimize Delamination Complaints in Oilpacks Products at PT XYZ Kreator Vol.
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Factor What Why Who Where When How - Focus on PO and resin to avoid mixing Check (Evaluatio.
Table 2.
Statistical Quality Control Pass Reject June 2024 Ae January 2025 No.
Month Production .
Defect .
Proportion UCL
LCL
June 2024 July 2024 August 2024 September 2024 512 October 2024 November 2024 320 December 2024 606 January 2025 After applying the PDCA method (Plan.
Do.
Check.
Ac.
, improvements were observed in the pass reject rate, which began to stabilize.
However, looking at the defect data, the graph remained stable initially (OctoberAeNovember 2.
but increased in the following months (December 2024AeJanuary 2.
In January, the graph slightly exceeded the upper limit.
Based on monitoring through the Control Chart, some defect data points exceeded the Upper Control Limit (UCL), indicating that the production process was out of control at certain times.
Although the PDCA method was applied to minimize delamination defects, this anomaly shows that there are still factors causing defects that have not been fully identified and eliminated.
This Fishbone Diagram illustrates the possible causes of Delamination grouped into four main categories: Man.
Machine.
Material, and Method.
A Man: Lack of control during the process.
A Machine:
o Insufficient glue supply o Insufficient ozone supply o Dirty extruder hood A Material: Material not according to specification.
A Method: Parameters not meeting standard and absence of a proper cleaning and inspection procedure.
Each of these categories contributes factors that may lead to the occurrence of delamination defects.
Kreator P-ISSN: 2354-9505 E-ISSN : 2548-9542 Kreator Vol.
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Figure 3.
Fishbone Diagram After the analysis using the PDCA (Plan.
Do.
Check.
Ac.
method, improvements were observed in the pass reject rate, which began to stabilize.
However, looking at the defect data, the graph was stable at first (OctoberAeNovember 2.
but increased in the following months (December 2024AeJanuary 2.
In January, the graph slightly exceeded the upper control limit (UCL).
Based on monitoring through the Control Chart, some defect data points exceeded the UCL, indicating that the production process was out of control at certain times.
Although the PDCA method was applied to minimize delamination defects, this anomaly shows that there are still defect-causing factors that have not been fully identified or eliminated.
Nevertheless, no complaints were recorded during the October 2024 Ae January 2025 period, indicating that the implemented method had a positive impact.
However, based on the control chart analysis, it was observed that during weeks 3 and 4, the proportion of delamination defect exceeded the Upper Control Limit (UCL).
This condition indicates the presence of special cause variation rather than normal process fluctuation.
Figure 4.
Bar Chart of Complaint Numbers June 2024AeJanuary 2025 Nazwa Febriyan/ Analysis of the Implementation of the PDCA Method to Minimize Delamination Complaints in Oilpacks Products at PT XYZ Kreator Vol.
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The results of the cause-and-effect .
diagram analysis reveal that the increase was correlated with several dominant factors, namely instability in ozone supply, inconsistent paraffin composition, and deviations in temperature and pressure parameters of the laminating machine.
Uncontrolled ozone supply reduces the bonding strength between material layers, thereby increasing the likelihood of delamination.
In addition, variations in paraffin content exceeding operational standards weaken material adhesion.
From the machine perspective, it was found that the actual heating temperature was lower than the established standard, resulting in suboptimal bonding performance.
Therefore, the increase beyond the UCL was not random but was triggered by technical factors identified through root cause analysis.
This finding demonstrates a direct relationship between statistical process monitoring results and quality analysis findings.
Act (Follow-Up Actio.
A quantitative analysis is required for anomaly points that exceed the Upper Control Limit (UCL) by conducting a time-based investigation to identify the specific conditions that occurred during defect spikes.
This evaluation may include tracing historical process parameter data, such as fluctuations in temperature, pressure, machine speed, and the stability of ozone supply during the same period.
This approach aims to determine whether the anomalies were caused by incidental factors, machine setting errors, material variations, or non-compliance with standard operating procedures (SOP.
In addition, the implementation of a more real-time and digitally documented monitoring system should be considered to minimize delays in detecting process deviations.
Re-standardization of the critical parameters that have been improved is also essential to ensure that the corrective actions are sustainable rather than temporary.
As a long-term strategic measure, the company may develop a more integrated quality control framework based on data-driven analysis and process risk assessment.
In this way, any deviation signals indicated on the control chart will be addressed not only through corrective actions but also through preventive measures supported by a more comprehensive control system.
CONCLUSION
Based on customer complaints recorded during the JuneAeSeptember 2024 period and the implementation of PICA (Problem Identification and Corrective Action.
conducted by PT Indofood CBP Sukses Makmur, two dominant causes of delamination were identified:
Paraffin droplets dripping onto the film area Insufficient ozone supply.
Both factors reduce the bonding strength between the two laminated films, resulting in delamination.
The paraffin droplets are caused by resin vapor that adheres to the extruder hood .
esin vapor collecto.
Over time, the paraffin accumulates on the inner wall of the hood, forming hardened resin deposits.
These deposits may eventually drip onto the laminated film surface, causing defects.
Meanwhile, the insufficient ozone supply is caused by applicators that have not been properly cleaned.
Ozone residue accumulates and forms deposits in the applicator holes, obstructing the ozone flow.
As a result, the ozone supply to the film decreases, leading to weak adhesion between the two film layers.
PT IXYZ has implemented the PDCA method through the PICA (Problem Identification and Corrective Action.
system to address delamination complaints.
However, delamination complaints have shown a fluctuating pattern, with inconsistent trends of For instance, two complaints were recorded in June, none in July and August, and the issue reappeared in September.
This fluctuation indicates the need for a more comprehensive reassessment using an appropriate method to identify the root causes of the delamination problem more thoroughly.
The corrective actions implemented include:
A Developing an ozone supply monitoring form A Creating an OPL (One Point Lesso.
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Following these improvements, no delamination complaints were recorded during the October 2024 Ae January 2025 period, indicating that the corrective measures had a significant positive impact.
However, based on the past reject control limit data, the defect rate exceeded the Upper Control Limit (UCL) in December, requiring further monitoring and control measures.
In January, the control limit value decreased again.
Therefore, further evaluation, investigation, and continuous improvement are necessary to ensure that the pass-reject rate remains within the established control limits and does not exceed the Upper Control Limit.
ACKNOWLEDGE
The authors would like to express their sincere gratitude to PT XYZ for granting permission and providing full support during the research process.
Appreciation is also extended to all production and quality control staff who contributed valuable data and insights for this study.
REFERENCES