QUALITY IMPROVEMENT IN PT X DYEING DEPARTMENT BYIMPLEMENTING SIX SIGMA (A CASE STUDY OF INDONESIAN TEXTILE COMPANY)

• Main Author: Aditya (19015049), Christianto
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/26257
• Institution: Institut Teknologi Bandung

PT X Textile located in Majalaya is considered as one of Indonesian major textile company <br /> <br /> that capable to produce almost any kind of fabric. As any other manufacturing companies, <br /> <br /> production process played a fundamental role on company’s development. In addition, defects <br /> <br /> in textile industry cannot be underestimated because the quality of finished goods depend <br /> <br /> almost altogether upon every process employed. The errors mostly happened in the Dyeing <br /> <br /> Department, simply because it’s the most complex, tricky and required significantly more time <br /> <br /> to operate than other processes. Latest data also shows that the percentage of defective product <br /> <br /> still exceeds company’s standard by 2 times. Hence, the objective of this research is to help PT <br /> <br /> X overcome the problem and improve their overall quality by implementing Six Sigma <br /> <br /> framework with DMAIC methodology. It deeply explores (1) company’s current production <br /> <br /> performance, (2) identify the root cause(s) that affect the quality of post-dyed yarn and (3) <br /> <br /> disclose them by providing remedial solution(s). The findings of this research are; (1) the <br /> <br /> Dyeing Department operated at 3 sigma level and yielded 6% of defects from total production <br /> <br /> in the year of 2017, (2) root causes are MAN (human error), MACHINE (power failure, broken <br /> <br /> part), MATERIAL (inferior chemical substances), METHOD (lack of quality control and <br /> <br /> formula pre-test) and (3) propose alternative improvement solutions (e.g. tighten HR <br /> <br /> management system, employ genset, establish responsive repairing service, order only from <br /> <br /> certified supplier, assign additional staff, conduct a formula pre-test) and control plan for each <br /> <br /> identified root cause.