Integration of Six Sigma, FMEA and TRIZ to improve product quality: Upright piano case application

Abstract

The high competition among manufacturing industry requires companies to perform the right business strategy. Quality becomes an important factor in that competition. Through product quality improvement, the industry will achieve a zero defect. The industry can improve the effectiveness of control in preventing defective products, then can reduce the waste of material, labor and costs. This study uses the integration of Six Sigma, FMEA and TRIZ methodsto reduce defects. The upright piano part which has the highest defect is Side Board R/L. The highest type of defect isclot from process (35,97%). The results shows that the average DPMO (Defect Per Million Opportunity) is 2547 and the sigma value is 4,3. Then an analysis of the cause of clot (process) is carried out using FMEA (Failure Mode and Effect Analysis) with highest RPN (Risk Priority Number) is 192. The dominant factor causing the product defect is operator handling. An improvement program is developed using the TRIZ (Theory and Innovative Problem Solving) method. The program consist of two recommended action, i.e. new design of cabinet shelf and the standard operational procedure to reduce the quality risk of operator handling.