Quality Control Analysis of Defective Products on Prism Sheets Using Lean Six Sigma with the DMAIC Concept

Firmansyah, Asep Priyanto, Pebrian Rahman Hakim, Daniel Sulaeman, Yoga Prasetyo and Yudi Prastyo
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Firmansyah: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530
Asep Priyanto: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530
Pebrian Rahman Hakim: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530
Daniel Sulaeman: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530
Yoga Prasetyo: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530
Yudi Prastyo: Department of Industrial Engineering, Faculty of Engineering, Universitas Pelita Bangsa, Jl. Kalimalang Inspection No.9, Cibatu, Cikarang Sel., Bekasi Regency, West Java 17530

International Journal of Research and Innovation in Social Science, 2025, vol. 9, issue 1, 2252-2261

Abstract: One method to improve quality is Lean Six Sigma with the concept of DMAIC (Define, Measure, Analyze, Improve and Control). It is oriented that there will only be 3.7 product defects from every 1 million products produced. This research aims to improve the quality of prism sheet products at PT XYZ, especially prism sheets that often have product defects. The results showed that there were 6 (six) types of product defects in prism sheets during the November 2024 period. Among them: Dirty, White Spote, Scratches, Crease, Ripped, Double Cut, From the calculation results, the average sigma level is 5,06 with an average DPMO value of 1030, Based on the pareto diagram, improvements are prioritized on the 2 (Two) most dominant types of defects. Namely the type of Dirty with a defect percentage of 90.05%, White Spote 5.69% Then a cause and effect analysis using fishbone is carried out, it is known that human factors, materials, machines, the environment and methods are factors causing two types of defects. In the improvement stage, improvement proposals are made using the 5W + 1H method as a form of improvement in quality improvement.

Date: 2025
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