Implementation of Packaging Material Cello Defect Control for Melvar 306 Gram Products Using the Define, Measure, Analyze, Improve, Control (DMAIC), Failure Mode and Effect Analysis (FMEA), and Kaizen Methods at PT. MAIJ2

Bakah Nurcahyo; Mochamad Eko Nugroho; Sita Kurniaty Ratoko

doi:10.55681/sentri.v5i8.7024

Authors

Bakah Nurcahyo Universitas Tangerang Raya
Mochamad Eko Nugroho Universitas Tangerang Raya
Sita Kurniaty Ratoko Universitas Tangerang Raya

DOI:

https://doi.org/10.55681/sentri.v5i8.7024

Keywords:

Six Sigma, DMAIC, FMEA, Kaizen, Packaging Defects, Quality Control

Abstract

Abstract: Quality is an important factor that determines a company's competitiveness. PT MAIJ2, a company operating in the food industry, faces quality issues related to defects in the Cello packaging material of Melvar 306 g products. The defect rate reached 7.05%, exceeding the company's quality standard of 2%. This study aims to identify the types of defects, determine the sigma capability level, and propose improvement recommendations. The research employed the Six Sigma method with the DMAIC (Define, Measure, Analyze, Improve, and Control) approach, supported by Failure Mode and Effect Analysis (FMEA) and Kaizen. In the Define phase, defect types and the SIPOC diagram were identified. The Measure phase involved determining Critical to Quality (CTQ) characteristics through the calculation of Defects Per Million Opportunities (DPMO), Sigma level, and p-control chart (P-Chart). The Analyze phase utilized Pareto diagrams, Fishbone diagrams, and FMEA to identify root causes and prioritize corrective actions. The Improve phase was conducted using the Kaizen approach with the 5W+1H method, while the Control phase focused on evaluating the implemented improvements. The results identified 13 types of defects in the Cello packaging material, with the three dominant defects being empty-package content defects (21%), packages trapped by the crimper (10%), and end-seal burst defects (10%). The average DPMO value before improvement was 70,487.55 with a Sigma level of 2.97σ. The FMEA results indicated that bent magazine forks and worn fingers (RPN = 576), improper Cello installation (RPN = 448), and unsuitable end-seal temperature settings (RPN = 200) were the main causes of defects. After implementing Kaizen improvements, the DPMO value decreased to 3,016.06 and the Sigma level increased to 4.25σ. These findings demonstrate that the implementation of DMAIC, FMEA, and Kaizen methods was effective in reducing defects and improving the quality of Cello packaging material for Melvar 306 g products at PT MAIJ2.

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