86 Journal of Applied Sciences.
Management and Engineering Technology.
Vol 5.
No 2, 2024: 86Ae95 Quality Control Analysis Using the Six Sigma Approach and Failure Mode and Effect Analysis (Fme.
As an Effort To Reduction Product Defects At CV.
Hikmah Jaya Convection Gatot Basuki HM 1 .
Yuli Wulan Dari 2 Industrial Engineering.
Institut Teknologi Adhi Tama Surabaya.
Surabaya Email: 1gatotbasukihm@itats.
id, 2yuliwulanyuliwulan@gmail.
Received: 2024-06-26 Received in revised from 2024-08-16 Accepted: 2024-10-11 Abstract CV.
Hikmah Jaya Konveksi is a company operating in the convection sector that serves companies, offices, campuses and schools, both private and government.
CV.
Hikmah Jaya Konveksi as a company operating in the convection sector was founded on January 26 2011.
CV.
Hikmah Jaya Konveksi is at the address Griya Kebraon Utara Vi No.
27 Surabaya.
The aim of this research is to identify types of product defects, find out the sigma level value for defective products produced and analyze the causes of product defects to provide recommendations for existing problems in the company so that it can reduce the level of defects in products.
The method used for this research is Six Sigma with the Define.
Measure.
Analyze.
Improve.
Control (DMAIC) stages by calculating the company's sigma value and Failure Mode And Effect Analysis (FMEA) for recommendations for improvements to the problem.
Based on the results of data processing and data analysis, 3 defects were obtained in the product, including skipped seams, wrinkled seams and slanted seams with an average sigma value of 4.
Based on the FMEA analysis, the proposed improvements given to minimize defective products are providing training related to sewing SOPs and conducting evaluations.
Leaders and Supervisors are responsible for defective products in their respective areas, conducting briefings for each line before production to clarify duties and respectively, providing lubricating oil to machine parts that have the potential to cause friction which causes noise, carried out periodically every 3 weeks, increasing supervision of all workers so that workers can focus when producing uniforms, checking machine maintenance, making maintenance scheduling regularly periodically every month 3 times.
Keywords : Defective products.
DMAIC.
FMEA
Introduction Currently, the world is increasingly competitive in meeting the needs of diverse consumers, companies must take strategic steps in managing their business.
Product quality has a significant effect on a company's performance.
Quality products are products that can meet buyers' needs .
Therefore, currently many companies are competing to innovate to attract consumer attention.
Innovation is important for consumers because it creates differences between one product and another .
However, the next most important thing is quality.
Quality products are the most important key to achieving excellence in market competition and will ultimately increase consumer satisfaction.
Each product definitely has superior quality and advantages compared to other products .
According to .
Product quality is the product's ability to produce results that meet or exceed consumer expectations.
Part of consumers consider product quality as the main factor in their purchasing decisions.
Product quality degradation often occurs during the production process, which can have a negative impact on the final product quality.
According to .
To reduce product damage, the right strategy is needed so that product quality is maintained .
Therefore, a process called quality control is needed.
From the problems above, researchers carried out quality control at CV.
Wisdom Jaya Konveksi uses the Six Sigma method and Failure Mode and Effect Analysis (FMEA).
According to .
Six Sigma is a quality control method that is often used, which is defined as an approach to improving quality and customer service which aims to achieve customer satisfaction.
The Six Sigma concept is carried out according to DMAIC (Define.
Measure.
Improve and Contro.
The advantage of the Six Sigma method is its focus on financial results that can be measured at the HM.
Quality Control Analysis Using The Six Sigma Approach And Failure Mode And Effect Analysis (Fme.
As An Effort To Reduction Product Defects At Cv.
Hikmah Jaya Convection organizational level.
This method helps analyze the root causes of product defects and presents suggestions for improvements in quality control.
According to .
FMEA is a methodology used to evaluate failures occurring in a system, design, process, or service .
Potential failure identification is carried out by assigning a value or score to each failure mode based on the occurrence level, severity level and detection level .
These three factors are used to calculate the Risk Priority Number (RPN) value which helps determine priorities for corrective action plans.
Failure Mode and Effect Analysis (FMEA) analysis is carried out at the Improve stage of the Six Sigma methodology.
The application of the FMEA concept at the Improve stage aims to produce structured improvement recommendations in the quality improvement plan, especially for dealing with defective products .
Method According to .
, in Six Sigma there is a Define.
Measure.
Analyze.
Improve.
Control (DMAIC) stage , which is a stage used to measure the implementation of Six Sigma and aims to improve continuously so as to achieve the Six Sigma target .
DMAIC starts from the Define (Identificatio.
Measure (Measuremen.
Analyze (Analysi.
Improve (Improvemen.
Control (Contro.
The following are the stages of DMAIC, namely:
Define Stage The first step in the Six Sigma approach , namely Define , focuses on identifying critical problems at the ongoing stage.
This stage also determines what is called Critical To Quality (CTQ) and makes observations on the production flow from the Supplier.
Input.
Process.
Output.
Customer (SIPOC) diagram.
Measure Stage The aim of this stage is to prove the problem from existing data.
To measure the problem, the Defects Per Million Opportunities (DPMO) calculation stage can be carried out to evaluate the company's current performance.
Calculating the DPMO and sigma value is carried out according to the Critical To Quality (CTQ) determination .
Analyze Stage Has the function of providing priority input on efforts to overcome the root causes of problems, showing the impact of failed processes and final products to consumers, as well as explaining the causes of process failures to the root causes of problems and providing input for improvisation Improve Stage Make various efforts to eliminate all causes of product defects and process failures.
Control Stage Has the function to supervise the implementation of improvement plans that have been created and planned .
According to .
Failure Mode And Effect Analysis (FMEA) is a structured procedure for identifying and preventing as many failure modes as possible, known as failure mode and effect analysis.
Following are several steps for completing Failure Mode And Effect Analysis (FMEA), namely:
Identify products and processes Make notes about possible problems that arise, their impact, and the factors that cause them Assess the level of severity ( Severity ), probability of occurrence ( Occurrence ), and detection capabilities ( Detection ) Calculate the Risk Priority Number (RPN), from the formula of multiplying the Severity.
Occurrence and Detection values .
FMEA is used to analyze services before they reach To calculate the RPN ( Risk Priority Number ) value for a process, initial knowledge of the value is required Severity.
Occurrence, and Detection first.
Results and Discussion 88 Journal of Applied Sciences.
Management and Engineering Technology.
Vol 5.
No 2, 2024: 86Ae95 Define Stage In the uniform production process, results will be obtained from the process which will later influence the number of rejections that arise from several defects in the production process.
Determination of CTQ in uniform production will focus on the production process.
Data collected to create CTQ ( Critical To Quality ) obtained through interviews with management and information from customers .
The following is the CTQ created and summarized by CV.
Wisdom of Jaya Konveksi, see Table 1:
Table 1 CTQ from the uniform production process No.
CTQ Uniforms Jump Stitch Creasing Seams Oblique Stitching Jump Stitch Skipping stitches occur because the operator is not careful, lacks focus, is tired and See Figure 1.
Figure 1 Skip-stitched uniforms Creasing Seams Shrinking stitches can occur due to lack of machine maintenance .
ewing machine performance is less than optimal, the machine stalls or die.
See Figure 2.
Figure 2 Puckered Seam Uniform Clothing HM.
Quality Control Analysis Using The Six Sigma Approach And Failure Mode And Effect Analysis (Fme.
As An Effort To Reduction Product Defects At Cv.
Hikmah Jaya Convection Oblique Stitching Slanted stitches are usually caused by cutting material that does not match the pattern See Figure 3.
Figure 3 Oblique Seam Uniform Measure Stage The measure stage is one of the operational steps in improving quality using the Six Sigma In the measure stage , control chart analysis will be carried out as well as calculations of DPMO and sigma values.
See Figure 4.
P- Chart Figure 4 Uniform Production Control Map Based on the calculated P- Chart results , it can be seen that the data obtained from the CL.
UCL and LCL calculations is proven to have no data that exceeds the upper and lower limits.
So it can be concluded that the data is in accordance with the control limits.
Defects Per Million Opportunities ( DPMO) Table 2 Calculation of DPMO and Sigma Level No.
Month March 2023 April 2023 May 2023 June 2023 Production Quantity .
2,991 5,862 4,870 3,798 Number of CTQs Number of Defects .
DPU
DPO
DPMO
Sigma 90 Journal of Applied Sciences.
Management and Engineering Technology.
Vol 5.
No 2, 2024: 86Ae95 July 2023 August 2023 September 2023 October 2023 November 2023 December 2023 January 2024 February 2024 Average 3,301 3,524 4,051 3,677 3,901 4,663 6,477 4,177 Based on the Table 2 calculating the DPMO value and sigma level of uniform production during the period March 2023 to February 2024, the Defect Per Million Opportunities (DPMO) value was obtained at 5106.
0 and then converted to the sigma table to 4.
It can be explained that the probability of damage is 5106 .
0 for a million production.
This shows that the DPMO pattern and sigma achievement are not yet consistent, which shows that the production pattern has not been managed properly and still needs improvement Analyze Stage At this analysis stage , each source of the problem will be explored to find a solution down to the root.
Therefore, analysis is needed to produce appropriate alternative solutions in accordance with the goals set by Six Sigma .
In completing this analysis stage .
Pareto and fishbone diagrams are used .
Pareto Chart The analysis carried out is to find out the biggest potential CTQ that influences the level of product defects.
To find out this, you can use the Pareto diagram.
Table 3 Pareto Diagram Analysis Results No.
Type of Defect Skip Stitches Creasing Seams Oblique Stitching Total Number of Defects(Unit.
Defect Percentage (%) Cumulative Percentage (%) From the Table 3, it will then be applied in the form of a Pareto diagram as follows:
Figure 5 Pareto Diagram for Uniform Clothing Products Based on Figure 5 the Pareto diagram, it can be seen that of the three levels of product defects in uniforms, the highest is product defects in skip stitching.
Fishbone Diagrams HM.
Quality Control Analysis Using The Six Sigma Approach And Failure Mode And Effect Analysis (Fme.
As An Effort To Reduction Product Defects At Cv.
Hikmah Jaya Convection The following is a bone diagram that researchers will present regarding the three types of defects in uniform products: skipped stitches, puckered stitches, and slanted stitches.
This diagram will help to identify the cause of the defect in the product, making it easier to find the best solution.
Figure 6 Fishbone Diagram of Uniform Defects Figure 6 is fishbone diagram, there are 20 root problems consisting of manpower, there are 5 root problems in it, namely the operator is not careful, is in a hurry to catch the target, the operator is not consistent, does not check the thread, does not fulfill the SOP ( Standard Operating Procedure ), then on the machine there are 3 root problems in it, namely wrong sewing machine set-up , lack of machine maintenance, scissors are not sharp enough, then in the method there are 5 root problems in it, namely the method of work is a little difficult to do, the sewing method is not precise, the needle and thread are not installed correctly.
, the sewing method is not optimal, the thread cutting method is wrong, next in the material there are 3 root problems in it, namely the fabric material is difficult to adjust, the type of uniform material is not suitable, the quality of the thread is not good, for the last one in the environment there are 4 root problems in it, namely temperature hot room, noise and dirty sewing area, lack of lighting.
Improve level At the improve stage , improvement proposals are made to minimize defects that occur in each process using the FMEA ( Failure Mode And Effect Analysis ) method.
FMEA is used to improve product and process quality performance.
In the FMEA table, a value or score is assigned to each failure mode based on the occurrence level , severity level and detection level From the results of scoring, the Risk Priority Number (RPN) will be known which is produced by multiplying the occurrence, severity and detection levels for each cause .
The following are the results of improvement using the FMEA method, see Table 4:
92 Journal of Applied Sciences.
Management and Engineering Technology.
Vol 5.
No 2, 2024: 86Ae95 Table 4 Failure Mode and Effect Analysis Process Name: Stitching Factor Potential Failure Modes Man Operators careful, less Operators Rush after the target Didn't Not with SOPs Machine 1.
Lack e .
ewing e is less than optimal, the Wrong set-up Scissors are sharp nor Material 1.
Fabric difficult to difficult to Inappropria te type of Thread quality is not good Potential Failure Effects Jump stitch, pucker stitch.
Oblique seam Potential Causes of Failure 3 Operator RPN Recommendation Rank Give yourself a few Oblique seam Operator is not focused.
Provide training to operators Jump stitch Provide enthusiasm and motivation to Increase supervision in each production line and provide SOP Seams Not SOP Jump stitch, pucker stitch.
Oblique seam Oblique seam Lack Lack Provide SOPs Schedule periodically 3 times a month Jump stitch, pucker stitch.
Oblique seam Lack Seams Seams Lack Fabric is too slippery or Provide SOP training to Check equipment before Operators must be thorough and careful when sewing Oblique seam Lack Seams Lack thread check HM.
Quality Control Analysis Using The Six Sigma Approach And Failure Mode And Effect Analysis (Fme.
As An Effort To Reduction Product Defects At Cv.
Hikmah Jaya Convection Method Sewing method is Jump stitch, pucker stitch.
Oblique seam Operators lack training Provide sewing SOP training to sewing conduct evaluations once a month Provide training and sewing skills tests to sewing operators The way it works is a difficult to Jump stitch, pucker stitch.
Oblique seam Lack ng of how things work Needle and thread sizes Seams The method is Thread Jump stitch, pucker stitch.
Oblique seam Lack ng regarding the use of needle and Lack ng of SOPs Provide training on SOPs for using needles and threads Provide sewing SOP training to sewing operators once a Oblique seam Not cutting SOP Lack of air no fan or like that Local workers do attention to Sewing music, and other tools make noise Provide training on thread cutting SOPs Environm 1.
Hot room Jump stitch, pucker stitch.
Oblique seam Add air ventilation Dirty sewing area Jump stitch, pucker stitch.
Oblique seam Always workers to clean work environments before and after Noise Jump stitch, pucker stitch.
Oblique seam Workers do attention to poorly lit.
Provide lubricating oil to engine parts potential to cause friction periodically and install sound provide additional Jump stitch, pucker stitch.
Oblique seam Based on the FMEA table above, there are 20 failure modes, but there are 6 failure modes that have the highest RPN values, namely the operator is not focused with an RPN value of 252, pursuing production targets.
RPN value 210 .
Failure to comply with thread inspection SOPs RPN value 175, lack of supervision RPN value 144 Lack of regular maintenance RPN 125.
Lack of training RPN value 100.
94 Journal of Applied Sciences.
Management and Engineering Technology.
Vol 5.
No 2, 2024: 86Ae95 Control Stage Control is the final stage in the DMAIC stage of the six sigma method .
At this stage, control and supervision is carried out to improve production quality and minimize defects through proposed improvements that have been provided.
The following are things that need to be done at the control stage .
Providing training related to sewing SOPs and conducting evaluations to operators once or twice a month.
An example of a sewing SOP is checking and preparing sewing equipment starting from needles, thread, scissors, and others according to the material to be sewn.
Leaders and Supervisors are responsible for defective products in their respective areas and are responsible for motivating employees to increase awareness of the work being done.
Conduct briefings for each line before production to clarify their respective duties and responsibilities and always focus on work to minimize product defects.
Providing lubricating oil to machine parts that have the potential to cause friction that causes noise, carried out regularly every 3 weeks and installing sound dampeners to reduce noise.
Increase supervision of all workers so that workers can focus while uniform production is .
periodic maintenance scheduling is carried out every 3 times a month to minimize damage to the sewing machine.
Conclussion Based on the previous discussion, it can be concluded that Critical To Quality determination stage, there are 3 types of product defects in uniforms, namely skip stitches caused by operators who are not careful and tired, wrinkled stitches caused by lack of machine maintenance .
ewing machine performance is less than optimal, the machine stumbles or die.
, skewed seams caused by inappropriate cutting of raw materials.
Based on data processing using the Pareto diagram, it can be seen that the most dominant level of defects in uniform clothing products is defects in skip stitching.
Proposed quality control and improvement based on implementation tools from FMEA (Failure Mode and Effect Analysi.
as follows :
Providing training related to sewing SOPs and conducting evaluations to operators once or twice a month.
An example of a sewing SOP is checking and preparing sewing equipment starting from .
eedle, thread, scissor.
according to the material to be sewn.
Leaders and supervisors are responsible for defective products in their respective areas and are responsible for motivating employees to increase awareness of the work being done.
Conduct briefings for each line before production to clarify their respective duties and responsibilities and always focus on work to minimize product defects.
Providing lubricating oil to machine parts that have the potential to cause friction that causes noise, carried out regularly every 3 weeks and installing sound dampeners to reduce Increase supervision of all workers so that workers can focus while uniform production is periodic maintenance scheduling is carried out every 3 times a month to minimize damage to the sewing machine.
Reference