SIX SIGMA FRAMEWORK IMPLEMENTATION IN A TEXTILE COMPANY

• Main Author: Mahdia Fatimah (NIM 19014009), Maulida
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/23005
• Institution: Institut Teknologi Bandung

PT.X is one of the batik companies in Pekalongan, Central Java, which produces sarong, skirt cloth, shawl, tablecloth, and bed linen. Among the five products, sarong and skirt cloth are the highest demand compared to other products, hence the both products are continuously produced. The organization is currently facing an operational management problem related to <br /> <br /> the product quality where defective items for sarong and skirt cloth are still exceeding the company’s acceptable limit, which is 2% of total production. This research is aimed to identify and disclose the main causes of the product’s defect problem and provide appropriate solutions to overcome the problem in PT X by using Six <br /> <br /> Sigma quality concept, which directs the organization to anticipate the occurrence of defective product and to do a continuous improvement by using define-measure-analyzeimprove-control cycle. This cycle is able to measure company’s performance level and identify the problem’s root causes so that alternative improvement solutions can be obtained. Quantitative and qualitative data taken from PT X indicate the critical factors during production and the company’s sigma performance level. The average defective of sarong and skirt cloth are reaching out 3.2% and 3.4%,respectively. Attribute (laney p-chart) control charts were performed to identify the process stability and the results indicated that the defect proportion during 2016 production is in control. Furthermore, the sigma levels for sarong and <br /> <br /> skirt cloth products are 3.99 and 3.97, however they specifically wants to reduce the defective percentage to be 2% which equivalents with 4.15 sigma level. A pareto analysis is then conducted to prioritize the defect types for the improvement. Ripped sarong and faint skirt cloth happened to be the most frequent defect. Both defects were analyzed to find the root cause using a fishbone diagram, which the results indicated that the root cause for ripped fabric is due to lack of raw material quality control. Hence, the proposed solution is to include a new quality control system prior to the production process to ensure the fabric condition and <br /> <br /> quality after receiving them from the supplier. In other hand, irregular machine maintenance is indicated as the root cause of faint skirt clothes. Hence, in order to overcome this situation is by conducting a regular maintenance. Incidental power interruption is also contributing the faint color problem, which can be minimized by installing a redundancy (back up) generator <br /> <br /> set so that it can assist steamer machine running continuously with very minimuminterruption. In conclusion, the company should develop a new quality control system, install a generator set, and do a frequent maintenance to improve the product’s quality. <br />