Strategi Six Sigma & FMEA untuk Mengurangi Cacat Produksi Keramik dan Mencapai Efisiensi di PT. Sun Power Ceramics
DOI:
https://doi.org/10.55606/jtmei.v5i3.6452Keywords:
Ceramic Defect, DMAI, FMEA, Quality Control, Six SigmaAbstract
This study aims to evaluate and implement a Six Sigma strategy to reduce ceramic product defects at PT Sun Power Ceramics and to improve production efficiency significantly. The research employs a quantitative approach based on the Six Sigma DMAI cycle (Define, Measure, Analyze, Improve). Data were collected from 14 production observations covering four primary defect types: chips (gumpil), cracks (retak), holes (lubang), and body contaminants (kotoran body). The analysis includes calculations of defect proportions (p), a p-control chart, DPMO (Defects Per Million Opportunities), sigma level, and process capability, followed by root-cause analysis using cause-and-effect (fishbone) diagrams and Failure Mode and Effect Analysis (FMEA). The results show a total of 6,402 defects, with chips being the most dominant type (28.2%). The overall process operated at an average sigma level of 3.01, an average DPMO of 66,272, and a process capability (Cp) of 1.003, indicating that the process is only moderately capable. FMEA identified cracks caused by excessive material moisture content as the highest priority, with an RPN of 504. Based on these findings, Six Sigma-based improvements such as standardizing moisture content, controlling the kiln, calibrating machines, training operators, and conducting routine inspections are recommended to reduce defects and move the process toward the zero-defect target, thereby improving product quality and operational efficiency at PT Sun Power Ceramics.
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