THE APPLICATION OF DMAIC AND DOE METHOD

IN OPTIMIZING REGRIND MATERIAL TO

INCREASE THE QUALITY PRODUCT IN PT. DY

By

Shofa Ramadhina

ID No. 004201500031

A thesis submitted to the Faculty of Engineering President

University in partial of requirements of Bachelor Degree in
Engineering Major in Industrial Engineering

2018
 Table of Contents
CHAPTER I ............................................................................................................ 1
INTRODUCTION .................................................................................................. 1
1.1 Problem Background ..................................................................................... 1
1.2 Problem Statement ........................................................................................ 2
1.3 Objectives ...................................................................................................... 3
1.4 Scope ............................................................................................................. 3
1.5 Assumption.................................................................................................... 4
1.6 Research Outline ........................................................................................... 4
CHAPTER II ........................................................................................................... 5
LITERATURE STUDY .......................................................................................... 5
2.1 Extrusion Blow Molding Machine .............................................................. 10
2.2 HDPE .......................................................................................................... 11
2.2.1 HDPE Color Master Batch (MB) ......................................................... 13
2.3 Six Sigma .................................................................................................... 13
2.4 DMAIC ........................................................................................................ 14
2.5 Design of Experimental ............................................................................... 15
CHAPTER III ....................................................................................................... 18
RESEARCH METHODOLOGY.......................................................................... 18
3.1 Problem Identification ................................................................................. 19
3.2 Literature Study ........................................................................................... 19
3.3 Data Collection ............................................................................................ 20
3.4 Data Analysis .............................................................................................. 20
3.5 Conclusion and Recommendation ............................................................... 21
3.6 Research Framework ................................................................................... 21
 CHAPTER I
INTRODUCTION

1.1 Problem Background

In the era of global competition, many manufacture industries are challenged to
produce good products in terms of quality and competitive prices (Douglas,
2009). According to Chopra and Garg (2011) only a product with good quality
products will be in demand, because the quality is the fulfillment of service to
consumers and prices are supporting factors for consumers to choose a product. In
business competition, every industry must be able to gain profit as much as they
can as one of determining parameters that business is going well or not. The
amount of profit is considered by strong sales and low costs in the production
process or other activities within the company (Charles, 2016).

According to Manzouri (2014), improving product and reducing costs are part of
the consent for each company. Therefore, the company must continue to strive to
increase productivity to fulfill the requirement of the customers and profit without
ignoring the quality of the products produced. In achieving this goal, the company
needs to make the process production runs optimally by optimizing of
manufacturing processes and parameters control (Khaldoun K and Ibrahim A,
2014). The major parameters affecting on the production line maintenance and
operations of the manufacture company.

PT. DY is a polymer company which provides wide variety of segments including

consumer packaging, component and industrial packaging in Indonesia and Asia.
The main machine in PT. DY is extrusion blow molding and it is still found
production problem that influence with the quality and quantity of product. Lot of
defect product give impact with increasing number of production waste and
influence with over consume raw material to fulfill the demand from the
customers. One of strategy have been applied in PT. DY is use a regrind as
supporting material in production process to reduce production cost. However,

1
there is no standardization of parameter control in the machine and make no
improvement situation of the current problem in production line.

Parameter setting machine influences with quantity and quality of product. PT.
DY produce product Evalube New Generation Green Color 800ml. At the
moment, the production bottle is not optimum. There were 620.948 pcs product
not fulfill the target of production and 100,667 kg of defect during January – July
2018. There are many parameters that influence with quantity and quality in
extrusion blow machine. In the previous research of the extrusion blow molding
(Khaldoun K and Ibrahim A, 2004) and (Darsin, Mahros et al, 2009) there are 4
variables influence which is blowing pressure, blowing time, melting temperature
and regrind (%).

The research aim is to find out the optimum cycle time and reduce numbers of
defect by varying those fours parameters to optimizing profit in PT. DY.
Optimization is carried out using response surface method. Response Surface
Methodology is one of method from design of experiment. These methods have
precise accuracy, efficient result, and suited for multiple response through full
factorial design, add center points to analyze the curvature (square) term that not
be determine by full factorial design or first order of RSM. This research will used
Box Behnken design as second order model of RSM which is need less runs of
experiment also can determine the curvature term rather than other method. Also,
the advantageous is those design not include the axial points or extreme points
(Montgomery, 2013).

1.2 Problem Statement

Based on the problem background that has been explained, the problem statement
of this research is:
1. What are the factors that affect to the weight?
2. What are the factors that affect to the cycle time?
3. How does determine and optimizing the responses through design of
experiment using combination level of factors?

2
4. What are the model equations that suitable and represent the relationship between
design factors and responses?
5. How well the optimization can improve the cycle time and profit in PT.DY?

1.3 Objectives
The objective of this research based on the problem statement above is:

1. Know the factors that affect to weight response

2. Know the factors that affect to cycle time response
3. To determine and optimizing the responses through design experiment by
analyzing the combination level of factor
4. To determine model equations that suitable and represent the relationship between
design factors and responses
5. To determine the comparison before and after optimization as a production
decision consideration in PT. DY.

1.4 Scope
Due to limited time and capability, there is a scope in this research:

 The experiment used machine Kautex KBB 60D which the product is 3 layers
 The experiment focused on Evalube New Generation 800ml.
 The resin use HDPE (High density polyethylene) Marlex HHM 5502 Natural,
masterbatch used MB Remafin Green MX-E1741 R2.
 The experiment using regrind material only in middle layer.
 The experiment conducted with one operator that operating in the machine, one
operator for material handling.
 The experiment conducted in 15x, 1 replication with 12 products each process
 The weight responses measured using digital weight gauge by one operator.
 The cycle time responses measured using stop watch digital by one operator.
 The preparation experiment conducted within July until August 2018.
 The experiment conducted in one week on 3th – 7th September 2018.

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1.5 Assumption
In doing this research, there will be assumption in order to make experiment
properly which are:
 The regrind material is clean and not contaminated with other material or dust.

1.6 Research Outline

Chapter I Introduction
This chapter explains the details of problem background, problem statement, and
research objectives to answer the problem statement, scope and assumption of
research as well as the research outline.
Chapter II Literature Study
This chapter consists of basic theoretical framework those taken from journals,
books and expertise works related with extrusion blow molding and response
surface method especially Box Behnken design in order to optimized parameter
process in plastic blow industries.
Chapter III Research Methodology
This chapter contains the general and detail process flow procedure from problem
identification to literature study, the steps or the flow in conducting the research
or project explained in this chapter. First using pareto chart, fish bone diagram,
Fitting the first order design of experiment response surface methodology: 2k Full
Factorial Design, Fitting the second order model: Box Behnken Design, Lack-of-
Fit Test, Response Optimizer, Residual Analysis, Correlation and Comparison of
KPI before and after optimization.
Chapter IV Data Collection and Analysis
The research and data observation are processed and analyzed in this chapter.
Current condition of defect and output product data collect from January until July
2018 in PT. DY. Then collect experiment result in order to reduce the defect
because of weight variable and increase the cycle time to fulfill the target
production of Evalube New Generation Green 800ml.
Chapter V Conclusion and Recommendation
This chapter contains answer of problem statements. Moreover, the conclusion
and recommendation is also made for further research.

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 CHAPTER II
LITERATURE STUDY
In this chapter consist of basic theoretical research framework which will be used
as a reference, procedures and steps in conducting research so that the issues will
be analyzed properly.

2.1 Basic Tools of Quality Control

There are 7 basic quality control tools, which can help an organization for solving
the problem and do improvement. In 1968 there was Dr. Kaoru Ishikawa who
proposed 7 basic tools by publishing a book “Gemba no QC Shuho” that
concerned in managing quality through techniques and practices in Japan
company. These 7 basic quality control tools, are:
1) Check Sheets
2) Histogram
3) Pareto Chart
4) Cause-and-effect Diagram (Fishbone)
5) Scatter Diagram
6) Control Charts
7) Stratification (flow chart or run chart)

2.1.1 Pareto Chart

Pareto chart was developed by Alfredo Pareto (1848 – 1923), he was an Italian
economist who worked with income and other unequal distributions in 19th
century. He was noticed there are 80% of the wealth was owned by only 20% of
the population. Pareto chart is a special histogram that can easily be apply to find
and prioritize problems in the organization (Montgomery, 2009).

Pareto chart is a type of bar chart that shows the relative importance variables,
prioritized in order from left to right side of the chart. The aim of pareto chart is to
show off the different kind of nonconformity from the data sources. Also, pareto
can generate a mean for investigating quality improvement improving efficiency
(cost reduction, material waste, energy, etc.). Figure 2.1 shows before and after
production improvement condition.

5
 Figure 2.1 Pareto Charts
2.1.2 Cause-and-Effect Diagram
In 1943 Dr. Kaoru Ishikawa was developed cause-and-effect diagram for root
cause analysis and concept of Quality Control (QC) circles. It also another name
for this diagram, there are Ishikawa diagram and fishbone because the shape looks
like the fish’s skeleton to identify quality problems based on degree of importance
(Neyestani, 2017). Cause-and-Effect diagram is problem solving tool that to
analyzes and investigates all the potential causes in single aspect.

Figure 2.2 Cause-and-effect Diagram

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There are 6 elements (causes) in generic categories of cause-and-effect diagram,
such as materials, environment, machine, measurement, method and man. Figure
2.2 shows the example potential cause of cause-and-effect diagram by arrows
entering the main cause.

2.1.3 Flow Chart Diagram

Flowchart presents a symbol including the inputs, activities, decision and output
to describe the steps exist in the process or operation. Flow chart diagram also as a
problem-solving tool to detect and analyze the process may be had potential
problems. So, the diagram is very useful to find and improve the quality through
the process (Forbes and Ahmed, 2011). Table 2.1 explain the type of symbol and
description, also figure 2.3 is the example of flow chart diagram.

Table 2.1 Symbols and Description in Flowchart

7
 Table 2.1 Symbols and Description in Flowchart (continued)

Figure 2.3 Flow Chart Diagram

2.2 Plastic

There are 2 types of plastics, thermoplastic and thermosetting or thermoset.

Thermoplastic is a plastic material which will heated to a certain temperature,
melts and can be formed return to forms such as film, fiber, packing (packing),
examples are: polyethylene (PE), polyprophylene (PP), and polyvinyl cgloride
(PVC). While Thermosetting is a plastic that has hard characteristics, retains its
shape and cannot be changed or changed back into its original form.
Thermosetting or thermoset can be used for parts of a car, part of aircraft and tires.

8
Thermoset examples are: polyurethanes, polyester, epoxy resins and phenolic
resin. Elastomers are plastic materials that have elasticity soft and usually non-
liquefying (Klein, 2011). Here below the classification of plastic:

Figure 2.4 Classification of Plastic

2.3 Extrusion Blow Molding Machine

2.2.1 Material

2.2.2 Factors on Process Variable

2.3 Design of Experimental (DOE)

2.4 Basic Experimental Design

2.5 Respond Surface Methodology

2.6 Lack of Fit Test

2.7 Residual Analysis

2.8 Responses Optimizer

2.9 Correlation Test

9
2.1 Extrusion Blow Molding Machine

According to Medraj (2016), blow molding machine is use in a manufacturing

process that to create hollow plastic parts by inflating a heated plastic tube to fills
a mold and forms the desired shape. The raw material in this process is a
thermoplastic (ex: HDPE) in the form of small pellets or granules, which is first
melted and formed into a hollow tube (parison). There are various ways of
forming the parison. The parison is then clamped between 2 mold halves and
inflated by pressurized air until it conforms to the inner shape of the mold cavity.
Lastly, after the part has cooled, the mold halves are separated and the part is
ejected.

Parts made from blow molding are plastic, hollow, and thin-walled, such as
bottles and containers that are available in a variety of shapes and sizes. Small
products may include bottles for water, liquid soap, shampoo, motor oil, and milk,
while larger containers include plastic drums, tubs, and storage tanks. Blow
molded parts can be formed from a variety of thermoplastic materials, including
the following:

 Low Density Polyethylene (LDPE)

 High Density Polyethylene (HDPE)
 Polyethylene Terephtalate (PET)
 Polypropylene (PP)
 Polyvinyl Chloride (PVC)

There are 3 principal techniques of Blow Molding, differing in the method by

which parisons are prepared. There are extrusion blow molding, injection blow
molding and stretch blow molding. In this research, the factory is use extrusion
blow molding in production process.

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Extrusion Blow Molding involves manufacture of parison by conventional
extrusion method using a die similar to that used for extrusion pipes.

Figure 2.1 Extrusion Blow Molding Production Steps

Extrusion Blow Molding is commonly used for mass production of plastic bottles.
The production cycle consists of the following steps:
 The parison is extruded vertically in downward direction between two
mold halves.
 When the parison reaches the required length the two mold halves close
resulting in pinching the top of parison end and sealing the blow pin in the
bottom of the parison end.
 Parison is inflated by air blown through the blow pin, taking a shape
conforming that of the mold cavity. The parison is then cut on the top.
 The mold cools down, its halves open, and the final part is removed.

2.2 HDPE
High Density Polyethylene (HDPE) is most commonly used in plastic industry.
Commonly HDPE found in milk jugs, plastic bags and refillable plastic bottles.
HDPE plastic has several properties that make it proper as a packaging for
manufacturing product. HDPE is stronger than standard polyethylene, acts as an

11
effective barrier against moisture and remains solid at room temperature. It resists
insects, rot and other chemicals. HDPE creates no risky emissions during its
production or during its use by the consumer. Also, HDPE leaks no toxic
chemicals into the water or soil.

Here below the physical, mechanical, thermal and electrical characteristic of High
Density Polyethylene (HDPE)

Figure 2.2 Characteristic of HDPE

According Klein (2017) said HDPE is strong and lasting construct, it also helps to
reduce the costs of maintenance. Product from HDPE have resistant surface is
resistant to scratches and impact dents. Most plastic surfaces that endure spray
paint or permanent marker aren’t easily cleaned. HDPE, on the other hand,
doesn’t require an expensive or time-consuming paint job. All plastic needs are a
simple cleaning of the surface, and the spray paint will be easily removed. Not
only will save money on paint, and time on the actual painting, but will also
impact with air quality

12
2.2.1 HDPE Color Master Batch (MB)
According Kutz (2011), Masterbatch (MB) is additive material for coloring plastic
(color masterbatch) or imparting other properties to plastics (additive
masterbatch). Masterbatch is a concentrated mixture of pigments encase during a
heat process into a carrier resin which is then cooled and cut into a granular shape.
Masterbatch allows the processor to color raw polymer economically during the
plastics manufacturing process especially for plastic industry who use HDPE
material in the process.

Masterbatch allows the industry or factory to keep stock of fewer number of the
polymer, and buy cheaper natural polymer in largeness. The masterbatch can be
fairly highly concentrated (in comparison with the target composition. Relatively
make thinner nature of masterbatches (in comparison with the raw additives)
allows higher accuracy in dosing small amounts of expensive components. The
compact nature of the grains of solid masterbatches eliminates problems with
dust, otherwise inherent for fine-grained solid additives. Solid masterbatches are
also solvent-free, therefore to have longer shelf life as the solvent won't evaporate
over time. The masterbatch usually contains 40-65% of the additive, but the range
can be as wide as 15-80% in extreme cases.

Figure 2.3 HDPE Color Masterbatch (MB)

2.3 Six Sigma
According to Snee (2004) defines Six Sigma is a business advancement strategy
that look for find and eliminate causes of mistakes or defects in the process by
focusing process output that are critical and importance to customer. The aim of

13
six sigma is to achieve and maintain the six standards between mean and nearest
specification limit, in other word six sigma describes quantitatively how process
perform. According to Jadhav, Ganesh P (2015) said Six Sigma is uniquely
because of close with customer demand, use of facts data, analytical statistic,
improving, and reinventing business processes. The proven benefits of the six
sigma “system” are diverse, there are:
 Market share growth
 Improvement of productivity
 Cycle time reduction
 Customer retention
 Culture change
 Development of service/product

2.4 DMAIC
The DMAIC is the classic Six Sigma problem-solving process. According to
Zbaracki (2002) said that DMAIC (define-measure-analyze-improve-control) is a
well-structured for eliminating defects, waste or of all kinds quality control
problems in manufacturing, service, management and other business activities.
DMAIC approach properly implemented can increase customer satisfaction,
quality and continuous improvement. The DMAIC use process step structure.
There are five steps to DMAIC approach, the steps are:

1. Define, make a good understanding of the problem make the improvement

much easier. Set the target and scope of the research project.
2. Measure, identities the defect and collect valid information of the research
project
3. Analyze, examine the collection data. The conventional analyze technique
like root cause analysis, cause and effect diagram and etc.
4. Improve, remove cause of defects from the process. This step is to
identify, test and implement a solution.
5. Control, make sure that defect not recur in the process. It defines as
monitoring and corrective action. The purpose this steps is to sustain in
new path optimization.

14
 Figure 2.4 DMAIC approach
2.5 Design of Experimental
According Anderson and Whitcomb (2007), design of experiment (DoE) is a
method of matrix-based multifactor does measure effects of interaction and
encompasses the multidimensional experimental region. DoE has become
important tool for development of product. In the beginning of DoE is focused on
model, criteria and many others exclusively for experiment and analysis step.
Applying DoE in industries is very complex because the scientific continues with
developing algorithms and design with mathematical properties. It was necessary
to adapt the DMAIC model in order to application of DoE. Here below the figure
model of methodology for applying DoE.

Figure 2.4 Model for Applying DoE

Can be seen on figure 2.4 need 2 steps, pre-analyze and experiment. A

hypothetical analyze step from the DMAIC divided into 3 steps and include the
selection of the experimental design in Pre-Analysis step and the analysis of the
data from experiment step Analysis step. Moreover there are the theoretical
concepts of the model. Firstly, the existing cycle stimulate not to conduct a one

15
shot experiment which is the experiments in more than one stage. Secondly, the
arrow connecting the Control and Define stages must be continuously improve the
whole process.

Every step of the model included of activities that must be completed before
continue to the next step. Here below the explanation of the task as the guidelines
of the process.
Figure 2.5 Activities for DoE Application

Figure 2.5 Activities for DoE Application (Continue)

16
Figure 2.6 Tools in Each the Methodology

17
 CHAPTER III
RESEARCH METHODOLOGY
Rajasekar et al. (2013) said research is an observation for unknown or additional
information that may be useful on a certain topic. It is an exploration of finding
problem solving to scientific and social problems through logical, systematic and
objective analysis. Rajasekar divides the prime objectives of research which are to
explore new facts, to prove and trial important facts and to interpret an event or
process or phenomenon to diagnose the cause and effect relationship. In this
chapter, there will be explanations about how the research is conducted.
Below is the detail of the research implementation starting from the preparation
until research in done.
 Determine the topic of the research by doing
Problem observation in current system
Identification  Define the research objective
 Formulate the scope and assumption of the research

 Extrusion Blow Molding

 High Density Polyethylene (HDPE)
Literature Study
 Six Sigma
 Design of Experimental (DoE)
 Object Research
 Collect the data of defect product and material
Data Collection consume
 Observe the current procedure of regrind
 Analyze the causes of defect product and material
consume
Data Analysis  Analyze the current procedure and new standard of
regrind process
 Analyze the experimental design and do
physical and mechanical quality check
Conclusion and
Recommendation  Conclusion of the analysis and calculation
 Recommendation for further research

Figure 3.1 Research Methodology

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3.1 Problem Identification
First step of the research is start with the problem identification that need to be
solved and having the opportunity for improvement. In this case the problem is
related with the optimization of regrind material (waste) from defect product in
PT. DY to increasing quality of the product. A problem statement is made to be
answered in this research. The objective is to optimizing the regrind material to
increase the quality of product in PT. DY. Because of the limited capability and
time, the research will be focused on bottle with 3 layers product and 1x
replication of experiment.. There is some assumption is made in this research, the
object research is the material of product use High Density Polyethylene (HDPE)
and use extrusion blow molding machine to manufacture the product It is defined
to make the research can achieved the objective of the research.

3.2 Literature Study

After identified the problem, the literature study is studied to strengthen the
research background and determined the method to solve the problem. The
literature study is the theoretical explanation and guidance on the chosen topic
which contains the detail explanation of the research that had done by the
researcher. In this research, there are some literature studies to be used as the
guidance in the process.

 According to Medraj (2016), extrusion blow molding machine is use in a

manufacturing process that to create hollow plastic parts by inflating a heated
plastic tube to fills a mold and forms the desired shape. The raw material in this
process is a thermoplastic (ex: HDPE) in the form of small pellets or granules,
which is first melted and formed into a hollow tube (parison).
 High Density Polyethylene (HDPE) is most commonly used in plastic industry.
Commonly HDPE found in milk jugs, plastic bags and refillable plastic bottles.
HDPE plastic has several properties that make it proper as a packaging for
manufacturing product.
 According to Snee (2004) defines Six Sigma is a business advancement
strategy that look for find and eliminate causes of mistakes or defects in the
process by focusing process output that are critical and importance to customer.

19
 The aim of six sigma is to achieve and maintain the six standards between
mean and nearest specification limit, in other word six sigma describes
quantitatively how process perform.
 According Anderson and Whitcomb (2007), design of experiment (DoE) is a
method of matrix-based multifactor does measure effects of interaction and
encompasses the multidimensional experimental region. DoE has become
important tool for development of product. In the beginning of DoE is focused
on model, criteria and many others exclusively for experiment and analysis
step.


3.3 Data Collection

Afterward, the data required regarding to the topic is collected for certain duration
of time. It can be short time because of less parameter, constraints, and variables
to be identified, otherwise for such a long time depends on the problem to be
solved. The first collection data will observe the object research which is the
bottle with 3 layers to get current condition of material composition and
characteristic of bottle. After that, there will be collecting data number of defect
and material consume. Last is to observe the current procedure of regrind process,
because this process is the key to find good quality of regrind.

3.4 Data Analysis

Collected data will be sorted and analyzed to be applied the purpose action. Firstly
the defect product and material consume will be analyzed to find the causes of the
condition. After find the cause will continue with analyze of the current procedure
of regrind process. Because this process is very important so analyze of the
process is very needed in order to get the solution. In the current process there is
no standardization of regrind process so the observation will focus to make the
standard of the process in order to keep a quality of the regrind material. After
find the solution in regrind process, the research will focused on optimizing the
regrind material to reducing over consume material in PT. DY. The
implementation is use experimental design to find best material composition and

20
physical and mechanical characteristic as a parameter of quality the product.
Lastly, will calculate the saving cost can be achieved from reduce the over
consume material from this research.

3.5 Conclusion and Recommendation

After retrieving the result, the conclusion is made to summarize all parts of the
research from the beginning until the result. It will show improvement idea in
production process with optimizing regrind material as supporting material, also
the best composition material for manufacture research object with the result of
quality checking the product and also the calculation cost if this research can be
implemented in PT. DY. After that the future research will be shows as the
recommendation in the future.

3.6 Research Framework

Previously in figure 3.1 only shows general framework of the research process
will conduct and will be explain more about the process of collecting data analysis
phases in figure 3.2.

3.6.1 Data Collection

The first step to be explained from figure 3.2 is about data collection. The
research cannot be conducted without data for the analysis. In some occasion, an
experiment should be held to support the research. In this research, the main topic
is optimizing regrind material to use maximized in production process with a good
quality of the product. This research only focuses on plastic bottle with 3 layers
surface, because this product consume much material than other product. The
bottle will be observed in order to get data collection, the data is about the
material composition and characteristic of the bottle. Also collect data regarding
number of defect 3 layer’s product and lastly to observed the processes of regrind
material Because this material is a key to reducing the over consume material in

21
PT. DY. After collecting whole data of the result of object research and material
record data, the data will be analyzed.

START

Design Research Object,

Scope and Assumption

Observed the object research

Will be analyzed using
Collecting data number of DMAIC method and
defect product and material build standardization
consume
Observed the current procedure Do experimental design
of regrind produce
NO

Verify?

YES

Calculate the cost

END

Figure 3.2 Detailed Research Frameworks

3.6.2 Data Analysis

After collecting data of the object research, the result data will be analyzed. The analyzed
is using DMAIC method to find analytical analyze and effective improvement action.
Firstly, analyze of object research will help to identify the characteristic of the product so
can build parameter as the standard for quality checking process. Second, the collected
data number of defect and material consume will know number of loss, so the data will
compare with result of purpose action. Lastly is analysis of the current procedure of
regrind produce. Regrind material will optimizing in this research in order to decreasing
consume material. In the real application the process should have a good procedure to get
a good quality of material for rework process. After whole the analyze will implement,

22
the improvement action use DoE to get the effective material composition. After
conducting the experimental design, the research object will be face quality check of
physical and mechanical characteristic. The last the object research from improvement
process will be calculated. Hopefully through the new system can improve the quality
product and increasing the profit in PT. DY by reducing material consume

23