Lean Manufacturing Integration in Reducing the Number of Defects in the Finish Grinding Disk Brake with DMAIC and FMEA Methods in the Automotive Sub Industry Company

Abstract

This automotive company is a company engaged in the automotive components of motorcycles. Its main product is Disk Brake. Automotive companies produced an average defective product in Disk Brake production for the January 2019 – December 2019 period of 1.72%, while the tolerance limit of the company was 1%, where there was a difference of 0.72%. This study aims to reduce the number of defects by providing recommendations for improvement proposals. The method used is DMAIC (Define, Measure, Analyze, Improve, Control) by calculating the company’s sigma value and using FMEA (Failure Mode and Effect Analysis) tools to improve the problem. The Define stage creates SIPOC and CTQ (Critical to Quality) diagrams. At the Measure stage, the results of the calculation of the sigma value obtained a DPMO of 3446.41 with a sigma value of 4.20. The most dominant type of defect in disk brakes is thin material based on the analysis results using the Pareto diagram at the Analyze stage. The causes of disk brake defects are obtained using a fishbone diagram. At the Improve stage, the FMEA calculation found the most potential problem-causing factors, namely the availability of components with an RPN (Risk Priority Number) value of 448 and 5W + 1H analysis, an improvement proposal was obtained to schedule maintenance and replacement of components regularly.