Production quality improvement analysis of grey cambric using Six Sigma Method

Abstract

Quality has an important role in business. A good quality means it is able to meet the required standards. The concept of quality must be comprehensive, whether the quality of the product or its process. PT Textile Yogyakarta is still having a high rate of defect products. The Waste Assessment Model (WAM) was used to identify the wastes that frequently occur by scoring each type of waste. The results show the waste rank are defect 26.12%, inventory 20.36%, motion 15.26%, transportation 14.51%, over production 12.91%, waiting 7.17%, and process 3.67%. While using the Six Sigma from the 4 CTQ process, the result of sigma level is 3.3. It means that the sigma level of PT Textile Yogyakarta is still under the average sigma level in Japan which is 5 Sigma. As for the improvement part, FMEA AHP was used and the results show that the first rank is the uncleaned woof residue, the second rank is the uncut thread which has an RPN value of 8.04 that was caused when the operator did not clean the machine from the woof residue, and the third rank is the malfunctioned machine which has an RPN value of 7.32 that was caused by broken kleting.