APPLICATION OF DMAIC AND TAGUCHI METHODS TO MINIMIZE THE DEFECTIVE PRODUCTS FLIP LIGHTSPEED CLIPBAR

Abstract

PT X is an industrial company that produces sandals including Lightspeed Clipbar,
Lightspeed Clip sandals and Lightspeed Cross Bar sandals. The problem that occurs is that
there is one sandal product with the highest level of disability, namely the Eiger Lightspeed
Clipbar sandal product which reaches 9,101% per year. The purpose of this study was to
identify the type of defect in the Lightspeed Clipbar sandal product through the DMAIC
stages (Define, Measure, Analyze, Improve, and Control)) and make a proposed
improvement in the assembling and buffing process at PT X. Based on the results of the
study, identified factors causing defects between Other: open bonding, the sides of the
sandals are not neat and the erosion of the Lightspeed Clip logo sandals. Factors that cause
sandals are defects, glue, soles and benzene. The DPMO (Defect per Million Opportunities)
value of the DMAIC results is 30376.12 with an average sigma score of 3.38. The sigma
value does not meet the sigma process capability standards for industries in developed
countries, which is 5-6 sigma. While the results of the Taguchi experimental calculations the
value of the average quality characteristics for sandals defects amounted to 3.40 to 0.32 and
the S / N quality characteristics of 10.67 to 0.24. The conclusion of this study resulted in
corrective action on the Eiger Lightspeed Clipbar sandals product, which is obtained the
optimal level setting of factors that affect the defects of Eiger Lightspeed Clipbar sandals,
including the 28g glue factor, 15 mm rubber soles and 13 mm benzene. Confirmation results
with an optimal setting level obtained values of 3.31 to 0.38, as well as S / N quality
characteristics for the defects of the Lightspeed Clipbar sandals 10.54 to 0.