Use of Six Sigma Methods to Reduce Packaging Defect in Sweetened Condensed Milk Sachets: A Case Study in XYZ Milk Industry, Indonesia

Abstract

The purpose of this study was to determine the causes of the defects in sweetened condensed milk sachets packaging of XYZ Milk Industry, Indonesia and take corrective actions on the problem. The use of Six Sigma method with DMAIC (Define, Measure, Analyze, Improve, and Control) is expected to increase sigma level. Pareto diagram, Ishikawa diagram, and why-why analysis were utilized as tools to analyze the cause of defects on products. Three major packaging defects were identified, namely horizontal leak, folded, and vertical leaks, which were caused by machine A, machine B, machine C, respectively. Based on the results of the analysis, the main problem was caused by inappropriate condition of the machine part such as dirty sealer, hollow on nozzle, and worn stator pump. By focusing on improvements of the problem, sigma level increased from 4.58 to 4.79. Therefore, periodic maintenance activities are important to do so that all machines may perform in its best conditions and comply with internal and regulatory quality standards.