Proposed Product Quality Control by Using Six Sigma Method, Fault Tree Analysis (FTA), Failure Mode and Effect Analysis (FMEA)

Authors

  • Yani Iriani*, Yeni Mulyani

Abstract

PT "X" Indonesia is a company engaged in the food sector that produces formula milk. This formula milk product is produced every day and defects are always found every month. The current problem is that in the past year there has been an increase in defective products by 4.35%, which exceeds the specified tolerance limit of 2%, resulting in a decrease in quality. This research was conducted by observing the production process and conducting interviews with the parties involved. The purpose of this study is to identify the causes of product defects using the Six Sigma method and provide suggestions for improvements using the Fault Tree Analysis (FTA) method and the Failure Mode and Effects Analysis (FMEA). The Six Sigma method is used to measure the Sigma Quality Level (SQL) based on the value of Defect per Million Opportunity (DPMO) of the formula milk production process. Fault Tree Analysis method is used to identify the causes of defects which become a reference for making improvements. The Failure Mode and Effect Analysis (FMEA) method is used to propose improvements based on the largest to the smallest Risk Priority Number (RPN) values ??for the causes of disability. Based on the results of Six Sigma processing, there are three types of defects, namely defects indicated by bacteria, defects in high lactose levels, and taste defects that are not according to standards. The results of calculations using the Six Sigma method obtained a DPMO value of 14,497.33 and a Sigma Quality Level value of 3.71. The results of the Fault Tree Analysis (FTA) show 7 factors that cause defects along with the Risk Priority Number value of the Failure Mode and Effect Analysis (FMEA) method which is a priority for improvement, including lack of discipline (384 RPN), less training (384 RPN), less thorough (288 RPN), lack of flushing monitoring (256 RPN), lack of knowledge (240 RPN), less swab monitoring (224 RPN), less organoleptic monitoring (224 RPN). The suggestions for improvements to be made are monitoring personal hygiene every day, conducting routine organoleptic and personal hygiene training, making product disposition forms, monitoring flushing and swabs, and sharing knowledge. The results of the improvement obtained a DPMO value of 6.72 and an SQL value of 5.93.

Published

2020-10-14

Issue

Section

Articles