Implementation of Six Sigma Methods with Failure Mode and Effect Analysis (FMEA) as a Tool for Quality Improvement of Newspaper Products (Case Study: PT. ABC Manufacturing – Sidoarjo, East Java – Indonesia)

Main Article Content

Muchammad Alfan Lutfianto
Rony Prabowo

Abstract

PT. ABC is a subsidiary of the JawaPos Group, founded in 1996, and is one of the companies in East Java engaged in printing and packaging. The products produced include magazines, books and newspapers. Of all the company's products, one of the most significant defects is found in newspaper products, which is 4% of the average newspaper production of 806.598 copies and produces a moderate defect of 22,743 copies in 2019. The research was conducted to analyze the sigma value and determine the factors of product defects and the impact of the defects to provide suggestions for product quality improvement. In this research, the method applied is the Six Sigma method and Failure Mode and Effect Analysis (FMEA), by implementing and carrying out the stages in the Six Sigma method, namely DMAIC (Define, Measure, Analyze, and Control). From this research, the results obtained are that the company has several newspaper product defects of 181,943 copies consisting of several types of product defects, including damp paper, blurred colours, shaded printing, asymmetrical printing, and running printing. The company is currently at the 4.04 sigma level, so corrective actions need to be taken to achieve six sigma levels. By applying the Failure Mode and Effects Analysis (FMEA) method, it can be seen that the most significant and most frequent product defect is the blurred colour defect. Therefore the recommended alternative solution for repairs is to check the ink and replace the ink with standard ink or have a lower density, perform regular and systematic machine checks, and provide further guidance on newspaper printing production standards to all operators involved.

Downloads

Download data is not yet available.

Article Details

How to Cite
Lutfianto, M. A., & Prabowo, R. (2022). Implementation of Six Sigma Methods with Failure Mode and Effect Analysis (FMEA) as a Tool for Quality Improvement of Newspaper Products (Case Study: PT. ABC Manufacturing – Sidoarjo, East Java – Indonesia). Journal of Integrated System, 5(1), 87-98. https://doi.org/10.28932/jis.v5i1.4615
Section
Articles

References

Armstrong, M. and Chen, Y. (2009) 'Inattentive consumers and product quality', Journal of the European Economic Association, 7, (2-3), 411-422

Bonfant, G. and Belfanti, P. (2010) ‘Clinical risk analysis with failure mode and effect analysis ( FMEA ) model in a dialysis unit’, Journal of Nephrology, 2010 ; 23 (01): 111-118

Chinomona, R. and Pooe, D. (2013) ‘The impact of product quality on perceived value , trust and students’ intention to purchase electronic gadgets’, Mediterranean Journal of Social Sciences, 4(14), pp. 463–472. doi:10.5901/mjss.2013.v4n14p463.

Gamal Aboelmaged, M. (2010) ‘Six Sigma quality: a structured review and implications for future research’, International Journal of Quality & Reliability Management, 27(3), pp. 268–317. doi:10.1108/02656711011023294.

Kim, J., Miller, B., Siddiqui, M. S., Movsas, B., & Glide-Hurst, C. (2018) 'FMEA of MR-only treatment planning in the pelvis', Advances in Radiation Oncology. doi:10.1016/j.adro.2018.08.024

Marques, P., Requeijo, J., Saraiva, P., & Frazão?Guerreiro, F. (2013) 'Integrating Six Sigma with ISO 9001', International Journal of Lean Six Sigma, 4(1), 36–59. doi:10.1108/20401461311310508

Mast, J. De and Lokkerbol, J. (2012) ‘An analysis of the Six Sigma DMAIC method from the perspective of problem solving’, Intern. Journal of Production Economics, 139(2), pp. 604–614. doi:10.1016/j.ijpe.2012.05.035.

Prabowo, R. (2012) ‘Analisa peningkatan kualitas produk keramik dengan menggunakan metode Six Sigma di CV. Glassmico Tile Tulungagung’, J.IPTEK.

Prabowo, R. (2016) ‘Analisis pendekatan Six Sigma sebagai pereduksi kecacatan produk herbisida cair 1 lt ( studi kasus : PT . Bayer Indonesia - Surabaya )’, Prosiding Seminar Nasional Sains dan Teknologi Terapan, 2022, pp. 231–244.

Sharma, K.D. and Srivastava, S. (2019) ‘Failure mode and effect analysis (FMEA) implementation : a literature review’, Journal of Advance Research in Aeronautics and Space Science, Volume 5, Issue 1&2 - 2018, Pg. No. 1-17

Sigma, S. et al. (2016) ‘Aluminium hot extrusion process capability improvement using Six Sigma’, Advances in Production Engineering & Management Journal, Volume 11, Number 1 March 2016, pp. 59–69.

Tjahjono, B. et al. (2010) ‘Six sigma: a literature review’, International Journal of Lean Six Sigma, 1(3), pp. 216–233. doi:10.1108/20401461011075017.

Wang, Y.M. et al. (2009) ‘Risk evaluation in failure mode and effects analysis using fuzzy weighted geometric mean’, Expert Systems with Applications, 36(2 PART 1), pp. 1195–1207. doi:10.1016/j.eswa.2007.11.028.