Pendekatan Lean Six Sigma untuk Meningkatkan Kualitas Produk dengan Mengintegrasikan Metode DMAIC, VSM dan VALSAT di PT. XYZ

Abstract

Quality is very important in the 4.0 era both in services and manufacturing. Every industry, especially the manufacturing industry, is required to be able to make products and sell competitive products to the market. PT. XYZ is a manufacturing company engaged in the production of food, namely biscuits, wafers and snacks. This research was conducted on the process of making biscuits. PT. XYZ experienced problems in terms of waste generated in the form of product defects and non value added activities. The large percentage of product defects experienced by PT. XYZ in 2022 is 7,15% with a company tolerance of 5% of total production. Types of defects in the form of cracks, chipped and sticky. In addition, the total non value added time was 22.77 minutes from 77.82 minutes of the total time. The non value added activities found were in the form of waiting and transfer activities. The purpose of this research is to reduce waste to improve product quality and reduce the level of product defects. The method used is the Lean Six Sigma approach with the integration of DMAIC, VSM and VALSAT which aims to reduce the number of defective products and non value added activities. Lean Six Sigma is a combination of lean and six sigma concepts. Proposed improvements use the 5W and 1H methods to determine priorities in improvements to improve product quality. The repair analysis is carried out using the VALSAT table to help find the causes of waste and Fishbone diagrams with the categories of humans, machines, materials, methods, and the environment can find the causes of product defects. From the results of calculations using the integration of DMAIC, VSM and VALSAT, it was found that the sigma level value increased from 3,46 to 3,61 with the DPMO value becoming 17.411 from 24.866. Apart from that, the non value added activities also eliminated 3 activities so that the non-value added decreased to 13,27 minutes from 22,77 minutes.