Six Sigma Analysis as an Approach to Improve Quality of Corrugated Zinc Sheet Product

Handy Nur Cahya

doi:10.33633/jpeb.v6i2.4638

Authors

Handy Nur Cahya Department of Management, Faculty of Economics and Business, Dian Nuswantoro University, Indonesia

DOI:

https://doi.org/10.33633/jpeb.v6i2.4638

Abstract

Every manufacturing company will strive to create the best quality products. This is also done by PT. CMSM, a steel company, is producing corrugated zinc products. In several production periods, the defective product values were still found that exceeded the tolerance limit value set at 0.5% in corrugated zinc products. These problems are, of course, very detrimental to the company, so it’s essential to control the quality of corrugated zinc products. This study aimed to determine the factors that cause product defects, propose plans to improve product quality, and provide managerial recommendations based on Six Sigma analysis. Data collection techniques are carried out through observation, interviews, and documentation. Based on the study results, it is known that DPO is 0.000885 and DPMO is 884.6028. At this time, the company is at the level of 4.64 sigma with CTQ (Critical to Quality) folded zinc sheet, cut size is not according to standard, thickness is not according to standard, uneven coating layer and perforated zinc sheet. Based on the analysis, five factors cause product defects: humans, machines, methods, materials, and the environment. To improve quality, the company should improve their quality control through 5W + 1H analysis, namely by providing training to employees, periodic machine maintenance and ensuring that the SOPs that have been made are implemented correctly and adequately. Keywords: six sigma, DMAIC, product defect, quality control, manufacturing

References

Afridi, F., Dhillon, A., Li, S. X., & Sharma, S. (2020). Using social connections and financial incentives to solve coordination failure: A quasi-field experiment in India’s manufacturing sector. Journal of Development Economics, 144, 102445. https://doi.org/10.1016/j.jdeveco.2020.102445

Anthony, M. B. (2017). Usulan Penurunan Tingkat Kecacatan Produk Pelat Baja Dengan Metode Six Sigma. 3(2), 41–48.

Ayhari. (2009). Manajemen Produksi (Edisi 4). BPFE.

Bozionelos, N., Lin, C. H., & Lee, K. Y. (2020). Enhancing the sustainability of employees’ careers through training: The roles of career actors’ openness and of supervisor support. Journal of Vocational Behavior, 117, 103333. https://doi.org/10.1016/j.jvb.2019.103333

Castro-Rodríguez, C., Solís-García, G., Mora-Capín, A., Díaz-Redondo, A., Jové-Blanco, A., Lorente-Romero, J., Vázquez-López, P., & Marañón, R. (2020). Briefings: A Tool to Improve Safety Culture in a Pediatric Emergency Room. Joint Commission Journal on Quality and Patient Safety, 46(11), 617–622. https://doi.org/10.1016/j.jcjq.2020.08.004

Choi, T. M. (2020). Innovative “Bring-Service-Near-Your-Home” operations under Corona-Virus (COVID-19/SARS-CoV-2) outbreak: Can logistics become the Messiah? Transportation Research Part E: Logistics and Transportation Review, 140(April), 101961. https://doi.org/10.1016/j.tre.2020.101961

Davis, D. L. G. & S. B. (2010). Quality Management for Organizational Excellent Introduction to Total Quality 6 th edition.

Desai, D. (2017). Competitive advantage through Six Sigma at plastic injection molded parts manufacturing unit A case study. 8(4), 411–435. https://doi.org/10.1108/IJLSS-06-2016-0022

Ferreira, J. J. M., Fernandes, C. I., Alves, H., & Raposo, M. L. (2015). Drivers of innovation strategies: Testing the Tidd and Bessant (2009) model. Journal of Business Research, 68(7), 1395–1403. https://doi.org/10.1016/j.jbusres.2015.01.021

Gaspersz, V. (2005). Total Quality Management. Gramedia Pustaka Utama.

GUAN, J. C., YAM, R. C. M., Tang, E. P. Y., & Lau, A. K. W. (2009). Innovation strategy and performance during economic transition: Evidences in Beijing, China. Research Policy, 38(5), 802–812. https://doi.org/10.1016/j.respol.2008.12.009

Heizer, Jay., dan R. B. (2017). Manajemen Operasi : Manajemen Keberlangsungan dan Rantai Pasokan, Edisi 11. Salemba Empat.

Heizer, J., Render, B., & Munson, C. (2017). Operations Management (12th ed.). Pearson Education, Inc.

Herron, C., & Hicks, C. (2008). The transfer of selected lean manufacturing techniques from Japanese automotive manufacturing into general manufacturing (UK) through change agents. Robotics and Computer-Integrated Manufacturing, 24(4), 524–531. https://doi.org/10.1016/j.rcim.2007.07.014

Hsu, M. H., Chang, C. M., & Chuang, L. W. (2015). Understanding the determinants of online repeat purchase intention and moderating role of habit: The case of online group-buying in Taiwan. International Journal of Information Management, 35(1), 45–56. https://doi.org/10.1016/j.ijinfomgt.2014.09.002

Huaccho Huatuco, L., Smart, J., Calinescu, A., & Sivadasan, S. (2020). Complexity transfer in supplier-customer systems. Production Planning and Control, 0(0), 1–13. https://doi.org/10.1080/09537287.2020.1762135

Indrawati, T., & Isnaini Dwi Ningsih, N. (2018). PENERAPAN STATISTICS PROCESS CONTROL DALAM PENGAMATAN SIFAT FISIKA DAN KIMIA AIR BUANGAN DARI AIR CONDITIONING (AC) Titik Indrawati 1 dan

Nunung Isnaini Dwi Ningsih 2. INTEGRATED LAB JOURNAL, 06, 39–46.

Islami, X., Mulolli, E., & Mustafa, N. (2018). Using Management by Objectives as a performance appraisal tool for employee satisfaction. Future Business Journal, 4(1), 94–108. https://doi.org/10.1016/j.fbj.2018.01.001

Jirasukprasert, P., Garza-Reyes, J. A., Kumar, V., & Lim, M. K. (2015). A six sigma and dmaic application for the reduction of defects in a rubber gloves manufacturing process. International Journal of Lean Six Sigma, 5(1), 2–22. https://doi.org/10.1108/IJLSS-03-2013-0020

Kelly, K., Valtchanov, D., & Webb, A. (2021). Behavioral implications of using an online slot machine game to motivate employees: A cautionary tale. Accounting, Organizations and Society, 89, 101196. https://doi.org/10.1016/j.aos.2020.101196

Kementrian Perindustrian Indonesia. (2020). Daftar Perusahaan Baja di Indonesia.

Kumar, S. A., & Suresh, N. (2007). Productions and Operations Management (2nd ed.). New Age International Publishers.

Kunamaneni, S., Jassi, S., & Hoang, D. (2019). Promoting reuse behaviour: Challenges and strategies for repeat purchase, low-involvement products. Sustainable Production and Consumption, 20, 253–272. https://doi.org/10.1016/j.spc.2019.07.001

Lyu, Z., Lin, P., Guo, D., & Huang, G. Q. (2020). Towards Zero-Warehousing Smart Manufacturing from Zero-Inventory Just-In-Time production. Robotics and Computer-Integrated Manufacturing, 64, 101932. https://doi.org/10.1016/j.rcim.2020.101932

Malviya, R. (2021). Agile manufacturing. In Lean Tools in Apparel Manufacturing (pp. 399–421). Elsevier. https://doi.org/10.1016/B978-0-12-819426-3.00011-4

Marques, P. A. de A., & Matthé, R. (2017). Six Sigma DMAIC project to improve the performance of an aluminum die casting operation in Portugal. International Journal of Quality and Reliability Management, 34(2), 307–330. https://doi.org/10.1108/IJQRM-05-2015-0086

Martin, J. W. (2008). Operational Excellence: Using Lean Six Sigma to Translate Customer Value through Global Supply Chains. Auerbach Publications.

Nair, M. S., & Salleh, R. (2015). Linking Performance Appraisal Justice, Trust, and Employee Engagement: A Conceptual Framework. Procedia - Social and Behavioral Sciences, 211, 1155–1162. https://doi.org/10.1016/j.sbspro.2015.11.154

Navío-Marco, J., Bujidos-Casado, M., & Rodrigo-Moya, B. (2019). Coopetition as an innovation strategy in the European Union: Analysis of the German case. Industrial Marketing Management, 82, 9–14. https://doi.org/10.1016/j.indmarman.2019.05.014

Nobori, J., Ishida, H., Inoue, A., Yoshikawa, T., Kimura, E., & Ishihara, K. (2014). EPA-0621 - Ultra-short daily briefings for sick-listed employees with psychological problems strengthen the sense of coherence in occupational healthcare. European Psychiatry, 29, 1–2. https://doi.org/10.1016/s0924-9338(14)78001-0

Pande, N., & Roland R.Cavanagh. (2002). The Six Sigma Way Bagaimana GE, Motorola & Perusahaan Terkenal Lainnya Mengasah Kinerja Mereka. ANDI.

Park-Lee, S. (2020). Contexts of briefing for service design procurements in the Finnish public sector. Design Studies, 69, 100945. https://doi.org/10.1016/j.destud.2020.05.002

Pete, & Holpp. (2002). What is Six Sigma. ANDI.

Prendeville, S., & Bocken, N. (2017). Sustainable Business Models through Service Design. Procedia Manufacturing, 8, 292–299. https://doi.org/10.1016/j.promfg.2017.02.037

Punyawan, S. E., & Rahardjo, J. (2015). Penurunan Kecacatan di PT Mulcindo Steel dengan Pendekatan Filosofi Six Sigma. 3(1), 7–14.

Pyzdek, T., & Keller, P. (2013). The Handbook for Quality Management. Mc Graw Hill.

Reichler, S. J., Murphy, S. I., Erickson, A. W., Martin, N. H., Snyder, A. B., & Wiedmann, M. (2020). Interventions designed to control postpasteurization contamination in high-temperature, short-time-pasteurized fluid milk processing facilities: A case study on the effect of employee training, clean-in-place chemical modification, and preventive maintenance programs. Journal of Dairy Science, 103(8), 7569–7584. https://doi.org/10.3168/jds.2020-18186

Render, B., & Heizer, J. (2001). Prinsip-Prinsip Manajemen Operasi. Salemba Empat.

Romdony, J., Lucky, M., & Rosmandi, N. (2018). Pengaruh Merek, Promosi, dan Kualitas Produk Terhadap Keputusan Pembelian Bola Sepak. Ikhraith-Humaniora, 2, 2.

Saghiri, S., & Wilding, R. (2021). On the effectiveness of supplier development programs: The role of supply-side moderators. Technovation, 103, 102234. https://doi.org/10.1016/j.technovation.2021.102234

Sanyal, M. K., & Biswas, S. B. (2014). Employee Motivation from Performance Appraisal Implications: Test of a Theory in the Software Industry in West Bengal (India). Procedia Economics and Finance, 11, 182–196. https://doi.org/10.1016/s2212-5671(14)00187-7

Schmuck, R., & Benke, M. (2020). An overview of innovation strategies and the case of Alibaba. Procedia Manufacturing, 51, 1259–1266. https://doi.org/10.1016/j.promfg.2020.10.176

Sharma, R., Gupta, P., & Saini, V. (2018). Six Sigma Dmaic Methodology Implementation in Automobile Industry: a Case Study 2. Journal of Manufacturing Engineering, 13(1), 42–050.

Slack, N., Brandon-Jones, A., & Johnston, R. (2016). Operations Management. In Pearson Education Limited (8th ed.). Pearson Education Limited.

Suresh, S., & Vasantha, S. (2021). Influence of logistics service quality among customer satisfaction using IOT based techniques. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2020.11.764

Tjiptono, F., dan Diana, A. (2012). Total Quality Management (TQM). Andi.

Tjiptono, F. (2003). Prinsip-Prinsip Total Quality Service. ANDI.

Tremblay, E., Hupper, A., & Waring, T. M. (2019). Co-operatives exhibit greater behavioral cooperation than comparable businesses: Experimental evidence. Journal of Co-Operative Organization and Management, 7(2), 100092. https://doi.org/10.1016/j.jcom.2019.100092

World Steel Association. (2019). World steel of figure 2020.

Younge, K. A., & Tong, T. W. (2018). Competitive pressure on the rate and scope of innovation. Journal of Economic Behavior and Organization, 150, 162–181. https://doi.org/10.1016/j.jebo.2018.03.026