Quality Control of Ceramic Wall Products Six Sigma Method with Dmaic Tools and Failure Mode and Effect Analysis (FMEA)

Abstract

Considering the importance of increasingly rapid industrial development, business people must be aware of the orientation towards product quality. The manufacturing industry has an important role in industrial development. It is hoped that it will be able to grow and have advantages in industrial development, therefore it is necessary to improve and increase product quality. The company continues to strive to maintain and improve product quality and increase productivity so that customers are satisfied with the products produced. One way that needs to be done is to reduce the number of defective products in the production process. This effort is one way of continuous improvement carried out by PT. ABC and companies operating in the same field. The ceramic wall production process has relatively high demand but still has a high level of defects. Based on information on production data and data on the number of defects for the period January – September 2023, wall ceramic production has a defect rate of 3.86%. Companies must reduce the number of defects to achieve company targets. This research aims to improve the production process of wall ceramics by minimizing the number of defective products. This research uses the six sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) tool assisted by the FMEA (Failure Mode and Analysis) method. Corrective action to reduce defects based on the 5 Why analysis is to find out what the problem is and ask "why" and "what is the root of the problem". The research results show that there are 4 types of defects which have a large number of defects, namely Rupture Defects, Application Defects, Peeling Defects and Hole Defects. From the research results, solutions were obtained for the emergence of several types of defects in the wall ceramic production process, namely by providing planning suggestions and corrective actions which are discussed this time. At the defect calculation stage, Broken produces a DPMO value of 29.362 with a sigma level of 3.39 with a sigma level of 3.48, Defect Peeled produces a DPMO value of 28.044 with a sigma level of 3.38, and holes are defective. resulting in a DPMO value of 26,020 with a sigma value of 3.45 from the data calculation results, it is still not enough to meet the company's target at the sigma level, therefore the company must make quality improvements to achieve the main target at the sigma level.

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