Analysis of Increasing Quality of Surfactant Powder at Oversize Parameter Using PDCA and FMEA in PT BCCI

Abstract

Quality of product is the important thing for PT BCCI in order to compete with other chemical industry of surfactant. In the production process of surfactant powder the particle size of the product is bigger than screener with mesh size 30 will produce oversize reaching 30% from every batch of products, indicates there is an issue that to be fixed immediately. This research was to find out the root of problem and action to improve the quality product and increase the output. PDCA and FMEA method were used to resolve these problems. The results are priority problem that needs to be improved based on the highest RPN value is the machine on the product evaporation system is the less working Vacuum maximum and the product temperature is less high. The product temperature need increase to 60°C which was previously 58°C and pressure on Vacuum <50 mbar. After improvement was applied the results obtained where the value of Cpk increased from 0.163 in the previous study to 3.609 and Oversize decreased from 30% to 20% in each batch process, this is in accordance with the target to be issued with the Oversize percentage below 30% in each process.