Quality Improvement Using The DMAIC Method To Reduce Defect Product In The PVC Compounds Industry

Abstract

Background: PVC Compound Industry is an industry that is engaged in the production of PVC Compound which is specially designed to meet the needs of the plastic industry market. The number of defective products produced by this industry is very large, so the quality of the company's products is low. The high number of defective products resulted in losses to the company. This study aims to reduce the rejection rate on PVC Compound. This research is a case study in the PVC Compound Industry.
Methods: This study uses the DMAIC method. This research is included in the mixed-method research. The data used include primary data and secondary data. This study uses Focus Group Discussion to analyze problems and provide suggestions for improvement.
Result: Based on data analysis, the three biggest defects are Surfacer, Dispert and Unmelt. Surfacer defect improvement is done by increasing the temperature and lowering the RPM. Improvements to the Dispert defect are by adding blending time and checking the blender temperature and steam pressure periodically. While the improvement on Unmelt is by lowering the screw extruder temperature, lowering the screw extruder RPM and lowering the RPM. The results showed that the DPMO value decreased from 909 to 252 and increased the average sigma level from 4.62 to 4.98.
Conclusion: This study concludes that with the DMAIC method the company can reduce the rejection rate and increase the sigma level.