Analysis of Cotton Yarn Product Defects in the Production Process of the Cotton Department Using the DMAIC Six Sigma Approach

Abstract

The smoothness of the production process is an indicator of success in increasing the effectiveness of a manufacturing industrial company. In the product manufacturing process, several types of defects occur , such as dirty thread, uneven thread rolls, tangled threads or non-standard loose thread rolls and others. This research focuses on finding types, defect factors , sigma values and RPN at PT. Indorama Teknologies Complex uses the DMAIC and FMEA Phase approach methods . In this research, researchers collected data by means of observation and interviews. Observations were carried out by direct observation at the research site taking place at PT . Indorama Teknologies Complex . Interviews were conducted with a question-and-answer session regarding the possible causes of product defects with production operators and supervisors in the field .

The average sigma value of the yarn production process cotton is 4.19 sigma. because there was a value that exceeded the control limit, a revision was carried out which made the sigma value increase to 4.22. The sigma value is still at level 4. Based on the 5W+1H analysis, the proposed improvement is strict supervision so that maintenance on the machine is carried out according to the schedule set by the company on a regular basis.