PERANCANGAN PERBAIKAN KUALITAS KAOS KAKI BABY PLAIN DAN BABY TERRY DENGAN KONSEP SIX SIGMA DI PT KAHATEX

• Main Author: Limenta, Shannen
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/48262
• Institution: Institut Teknologi Bandung

PT KAHATEX is a company engaged in textile industry. One of the highest demand products in 2019 is socks. To maintain the company’s reputation and client’s trust, the company focuses on quality of the product. However, products that are produced in KK7L production area in PT KAHATEX have a high defect rate. Based on the production data from January to October 2019, the defect rate of Plain babies’ socks is 13.54% and the defect rate of Terry babies’ socks is 12.47%. High defect rate would reduce client’s trust towards the company. This study proposes quality improvement design of babies’ socks using Six Sigma methodology with DMAIC (Define, Measure, Analyze, Improve, Control) approach in PT KAHATEX. In the define phase, the object of the study is determined, which are Plain babies’ socks and Terry babies’ socks that are being produced in KK7L production area. In the measure phase, the stability and capability of the production process is being measured with sigma value of 2,334178 for Plain babies’ socks and sigma value of 2,53614 for Terry babies’ socks. In the analyze phase, using pareto chart and other consideration to determine 4 types of defects. Analyze phase also determine the factors and sub-factors that cause the defects by using Delphi method and visualize them in Cause and Effect Diagram. These prioritized factors and sub-factors are selected by Failure Mode and Effect Analysis (FMEA) method, by selecting factors and sub-factors of each defects type that got the highest RPN value or more than 130 RPN value. In the improve phase, there are 7 alternative solutions that are accepted by the company. In the control phase, implementation schedule and SOP (Standard Operational Procedure) are arranged to ensure the implementation of alternative solutions are carried out properly. The result of this study indicates that Plain babies’ socks and Terry babies’ socks have 8 types of defect, but defects that contribute the most to the low quality of the babies’ socks are hollow, dirt, non-symmetrical, and off-track defects. There are 7 critical factors that cause defects in Plain and Terry babies’ socks at PT KAHATEX. From a total of 31 sub-factors that are identified as the cause of defects using Delphi method, 5 sub-factors are chosen based on RPN value to be solved. Based on the chosen sub-factors, there are 7 out of 8 alternative solutions that are accepted by the company. Company needs to update documents, provide socialization and training to operator, adjust the workload of each employee that are affected by alternative solutions, and evaluate the results of implementing solutions.