PRODUCT DEFECT REDUCTION USING QUALITY PLANNING IN FURNITURE MANUFACTURING

• Main Author: Nawang Wulan, Putri
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/71650
• Institution: Institut Teknologi Bandung

Approximately 68 percent of the millions of hectares of forestland in Indonesia are designated as production forests. With a CAGR of more than 4.2%, the furniture industry's potential nature indicates a bright future. There are five local players who dominate. However, technological advancement and product innovation are helping midsize and smaller businesses expand their market presence. Indonesian furniture manufacturers are competing as the value of furniture and home furnishings rises and the number of manufacturers increases. SME furniture should also create and implement strategies that outperform competitors and increase customer value. One SME furniture manufacturer, PT Papan Kreasi Apike, has received many product defect complaints, affecting its profits.. They are predicted to lose 5% of their profit each year due to this problem. This study investigates the causes of defect products that result in a profit decline. Based on company observations, stakeholder interviews, distributed questionnaires, and literature reviews, the root cause was reached. With DMAIC six sigma roadmap and analysis tools such as Eight Waste of Lean Manufacturing, Current Reality Tree and SIPOC, it found that unprecise door, fracture, unfulfilling finishing, unsymmetric closing level, unergonomic product, unfitted with the site, untidy stitches, and last a varied pattern direction in one product are the type of defect that frequently arise. This firm lacks product quality standards as evidenced by the absence of quality control. This study will interpret quality planning by finding the root cause of the defect then developing a solution. The root cause has been identified, but the company's production process is flawed due to a lack of project evaluation. In order to address the problem, three alternative solutions were proposed: control charts to monitor progress, standards to generate guiding principles, and training for workers to develop a keen eye for detail. To determine which solutions should be proposed, this study utilized AHP analysis with three known factors: impact, ease, and cost. With 0.56 points, the results demonstrate that control chat is favored and has a greater impact. In an effort to reduce product defects, the company has agreed to implement a control chart as a first step.