Reducing waste in production process with lean six sigma approach and weighted product method

• Published in: IOP conference series. Materials Science and Engineering Vol. 505; no. 1; pp. 12055 - 12062
• Main Authors: Siregar, Khawarita, Ishak, Aulia, Purba, Trie Dinda M
• Format: Journal Article
• Language: English
• Published: Bristol IOP Publishing 01.05.2019
• Subjects: Inspection; Lean manufacturing; Pesticides; Six Sigma
• ISSN: 1757-8981; 1757-899X
• DOI: 10.1088/1757-899X/505/1/012055

PT XYZ is a company engaged in the production of pesticides. There are some problems in production process that cause inability to full fill the production quantity target without doing overtime. the problem is the existence of activities that are not value-added and products defect. There are 48,73 % non value added activity and in 2017 the average of products defect reaches 3.89% of total production. This can affect the quality of the products produced to compete with similar companies. This problem is solved by Lean Six Sigma approach. Based on research conducted Lean current condition is PCE (Process Cycle Efficiency) equal to 51,27%, process velocity equal to 0,082 process / hour. The research shows that quality performance at the first phase inspection was 3.77 sigma, on phase II was 3.85σ. The most common product defect is a leaky bottle, an oblique stamp, a torn/wrinkled label and a missing / blurry label. The proposed improvements are the application of the 5S and weighted product method. Based on estimation result, the process cycle efficiency and process velocity was increased to 55.07% and 0.071 process/hour respectively, Quality performance in the inspection phase I is 4.20 σ and on phase II is 4.40 σ.