Quality control analysis to reduce defect product and increase production speed using lean six sigma method

Abstract

CV. Naga Mas engaged in manufacturing spare part. Support assy is one of the products that manufactured by the company. The product has an average disability percentage 9.49% of the total monthly production which exceeds the limits of the company. This study propose to increase production speed by to eliminate non value added activities and reduce the amount of disability products through design improvements. This problem solved with Lean Six Sigma approach with the combination Lean and Six Sigma concepts by using DMAIC steps to propose improvements through eliminate non value added activities and reduce the amount of defective products. Proposed improvements given that eliminate non value added activities and micro layout redesign settings. Based on estimates, the result for the process lead time reduction is 22.01 min / cycle process, increasing process efficiency and process cycle velocity, respectively for 7.80% and 0.0008 processes / h. Improvement plans are using 5S method such as sorting, arrangement, cleaning, consistency and self discipline that makes work programs in making machines, makes work procedures, inspects raw material, improves communication with suppliers and manages regular machine maintenance.