INTERNSHIP AT PT.

XI
AN APPLICATION OF DMAIC AND
STATISTICAL PROCESS CONTROL METHODOLOGY
FOR MINIMIZING DEFECT PERCENTAGE
IN ROTOCAST AREA OF PT. XI

Presented by:
Tara Septriana
004201100027
 ABSTRACT

 PT. XI located in Jababeka is a doll manufacturer

 Doll’s head is very important  decision point for customer
 Defect on the heads  customers will not buy
 Doll’s head made from rotocast process faces many defects
 Reduce defects  increase output  acceptable by customer
 DMAIC and Statistical Process Control methodology is used
INTRODUCTION

 Problem Background
 Problem Statement
 Objectives
 Scope
 Assumption
 Research Outline
PROBLEM BACKGROUND

 Rotoheads made from rotocast process faces some defective

products
 Defective products  reduce output and increase scrap cost
 Defective products need to be reduced
 DMAIC and Statistical Process Control is used  detect the
process  affect the change in product’s quality
PROBLEM STATEMENT

 How DMAIC methodology and Statistical Process Control

methodology are able to reduce defect at rotocast area?
RESEARCH OBJECTIVES

 To use DMAIC methodology and Statistical Process

Control methodology in order to reduce defect at rotocast
area
 To proposed the improvement result.
SCOPE

 The research is conducted on rotohead from rotocast

machine.
 The data of defects are collected from rotocast area for shift
2 only for both the historical data and improved data.
 The data is only applicable to be used in PT.XI – Rotocast
area
 This project is done from June - July, 2014.
ASSUMPTIONS

 The working condition is always the same during trial.

 The historical data (shift 2) can represent the data for the
other shift.
RESEARCH OUTLINE

 Chapter I Introduction
 Chapter II Literature Study
 Chapter III Research Methodology
 Chapter IV Company Profile and Project
 Chapter V Data Collection and Analysis
 Chapter VI Conclusion and Recommendation
 LITERATURE STUDY

• QUALITY  IMPORTANT FACTOR FOR CUSTOMERS IN

DECIDING ON BUYING A PRODUCT
• QUALITY: INVERSELY PROPORTIONAL TO VARIABILITY
• QUALITY IMPROVEMENT  REDUCE VARIABILITY OF
PRODUCT
• VARIABILITY SHOWN BY USING STATISTICAL TERMS
SIX SIGMA
– DMAIC– SIX SIGMA– DMAIC– SIX SIGMA– DMAIC– SIX SIGMA– DMA

LITERATURE STUDY (CONT’D)

• SIX SIGMA  IMPROVEMENT STRATEGY FOCUSES ON PROCESS
IMPROVEMENT
• DMAIC  SIX SIGMA METHODOLOGY
• DEFINE: IDENTIFY PROJECT OPPORTUNITY AND GOAL
• MEASURE: EVALUATE AND UNDERSTAND THE CURRENT PROCESS
• ANALYZE: UNDERSTAND THE DIFFERENT SOURCES OF
VARIABILITY
• IMPROVE: BRAINSTORMING ON FINDING SOLUTION
• CONTROL: GIVE IMPROVEMENT RESULT AND MAINTAIN THE
IMPROVEMENT

X SIGMA
– DMAIC– SIX SIGMA– DMAIC– SIX SIGMA– DMAIC– SIX SIGMA– DMAIC
 LITERATURE STUDY (CONT’D)
• Statistical Process Control (SPC)  DMAIC tools
used to improve quality through variability reduction
• SPC  7 QC tools
1. Process Flow Diagram 1. Pareto Diagram
2. Fishbone Diagram 2. Scatter Diagram
3. Control Chart 3. Histogram
4. Check Sheet
 PROBLEM FINDING

RESEARCH
OBJECTIVES

RESEARCH
LITERATURE STUDY

METHODOLOGY
DATA COLLECTION

DATA &
IMPROVEMENT
ANALYSIS

CONCLUSION &
RECOMMENDATION
PROBLEM FINDING
• How DMAIC methodology and Statistical Process Control methodology are able to
reduce defect at rotocast area?

RESEARCH OBJECTIVES
• To use DMAIC methodology and Statistical Process Control methodology in order
to reduce defect at rotocast area
• Proposed the improvement result
LITERATURE STUDY
• Research Topic:
• Quality Improvement
• Six Sigma
• DMAIC Methodology
• Statistical Process Control
• The 7 QC Tools
• Source: books, research journals, and lectures notes
 DATA COLLECTION
HISTORICAL DATA

DIRECT OBSERVATION
DATA & IMPROVEMENT ANALYSIS
• Data Analysis
• Cause and effect analysis
• Improvement Analysis
• Improvement proposal for each factor on analysis
• Applying the improvement proposal to production line
CONCLUSION & RECOMMENDATION
• Conclusion  The improvement and result of the research
• Recommendation  suggestions for future research
COMPANY PROFILE
• PT. XI
• Located in Jababeka, Cikarang
• Produce fashion dolls
• Established in October 1991
• It has 2 production plants in Jababeka  East Plant and West
Plant
• East Plant was build in September 1996
• Started production process in October 1997
COMPANY’S VISION &
MISSION
• Vision
“Partner for Growth in the Future of Play through Continuous
Innovation”

• Mission
To be the leading toy manufacturer of toy brands through
globally competitive and continuous innovation
COMPANY
PRODUCTION
SYSTEM
INTERNSHIP AT PT. XI
• Internship period: 26th March – 15th August 2014
• Projects:
• Reduce Blackspot
• Reduce Bubble defect
 DATA COLLECTION &
ANALYSIS
DEFINE
MEASURE

ANALYZE
DEFINE
 DEFINE (cont’d)
02 June 03 June 04 June 05 June 06 June 07 June
Defect Total
2014 2014 2014 2014 2014 2014

Blackspot 906 1,037 937 873 725 883 5,361

Bubble 296 307 437 725 504 408 2,677

Burn - - 70 30 7 19 126

Cap 464 438 441 256 345 367 2,311

Others 165 133 179 29 82 73 661

Scratch 79 1 24 32 31 25 192

Uneven - - 30 120 - - 150

Total Defect 11,478

MEASURE

Cumulative
Defect Total Percentage PPM
Percentage
Blackspot 5,361 46.71% 46.71% 7,648.91
Bubble 2,677 23.32% 70.03% 3,819.46
Cap 2,311 20.13% 90.16% 3,297.26
Others 661 5.76% 95.92% 943.09
Scratch 192 1.67% 97.60% 273.94
Uneven 150 1.31% 98.90% 214.02
Burn 126 1.10% 100.00% 179.77
Total Defect 11,478
BLACKSPOT
MC-
02 June 03 June 04 June 05 June 06 June 07 June
Head Total
2014 2014 2014 2014 2014 2014
Number
1104 67 117 100 79 68 75 506
1114 61 39 77 69 70 85 401
1110 65 38 66 37 38 89 333
976 39 46 43 45 16 25 214
1064 19 40 27 19 25 32 162
1160 23 27 26 23 26 35 160
1069 38 31 44 34 147
1077 24 30 23 13 24 28 142
1165 27 23 22 26 16 28 142
611 45 27 33 31 136
 BUBBLE
MC-
02 June 03 June 04 June 05 June 06 June 07 June
Head Total
2014 2014 2014 2014 2014 2014
Number
1166 139 76 204 36 26 481
1039 34 321 25 43 423
1159 24 26 101 30 71 85 337
1167 61 58 49 39 15 50 272
1069 90 103 193
1113 35 4 19 42 100
1064 52 47 99
1171 10 35 40 85
1172 20 20 43 83
1165 22 7 20 19 8 76
ANALYZE
ANALYZE (cont’d)
IMPROVEMENT ANALYSIS
IMPROVE

IMPROVEMENT
RESULT

CONTROL
 BLACKSPOT
Factor Cause Improvement Suggestion

Contaminated Add filter to the plastisol tank

Material
Plastisol tank
Make sure that the tank is
is not
closed after refill
properly
closed

IMPROVE
 BLACKSPOT (CONT’D)
Factor Cause Improvement Suggestion

Lack of training

Man New Hire Provide adequate training

Inexperienced
operator

Improve supervision from

Poor behavior
leaders

IMPROVE
 BLACKSPOT (CONT’D)
Factor Cause Improvement Suggestion

Dirty Clean the machine regularly

Machine
Lack of
Make sure that the spray gun
maintenance
and vacuum are functioning

IMPROVE
BLACKSPOT (CONT’D)

Factor Cause Improvement Suggestion

Different Make uniformity in method

cleaning
method
Method Blister usage Remove blister usage

No SOP Make SOP for operator 1

IMPROVE
 BUBBLE
Factor Cause Improvement Suggestion

Viscosity Standard viscosity: 0.9 Poise

Plastisol Tank Refill tank regularly

Material

Mold Replace defective mold

condition
IMPROVE Maintain mold temperature
 BUBBLE (CONT’D)
Factor Cause Improvement Suggestion

Lack of training

Man Provide adequate training and

New Hire
Improve supervision from
leaders
Inexperienced
operator

Room Lowering the room

Environment Temperature temperature

IMPROVE
 BUBBLE (CONT’D)
Cycle Oven Machine Bubble Rotohead
Trial Oven temperature
time time rotation defect condition
Standard 140 110 240 °C – 260 °C 32 Hz / 22 Hz
1 140 Machine
120 setting
245 °C Find
32 Hz the best machine
/ 22 Hz 15 setting
Good
2 140 120 240 °C 32 Hz / 22 Hz 11 Undercooked
3
Machine 160 125 240 °C 32 Hz / 22 Hz 13 Good
4 160 130
Lack of 240 °C 32 Hz / 22 Hz 12 Good
5 180 130 240 °C
Maintain the machine
32 Hz / 22 Hz 12 Overcooked
maintenance
regularly
6 180 130 235 °C 32 Hz / 22 Hz 8 Good

IMPROVE
IMPROVEMENT RESULT
1104 BEFORE AFTER
Weekending (Shift 2) 07-Jun 21-Jun
Defect (pieces) 506 321
Total output (pieces) 1,747,438 1,725,862
PPM 289.48 185.96
Defect Reduction (%) 35.76

1166 BEFORE AFTER

Weekending (Shift 2) 07-Jun 28-Jun
Defect (pieces) 481 215
Total output (pieces) 1,747,438 1,907,616
PPM 275.18 112.69
Defect Reduction (%) 59.05
CONTROL
 New hire  understand method and the importance of
reducing defect
 Maintain tools regularly

 Create maintenance schedule

 Conduct training session for operator

 Create SOP

 Implementing discipline to leaders and operators

 CONCLUSION &
RECOMMENDATION
O Conclusion
O DMAIC and Statistical Process Control methodology can
reduce blackspot defect in rotocast area of PT. XI by 35.76%
and bubble defect by 59.05%
O DMAIC and Statistical Process Control are the methods that
can be used by other researchers to make improvement for
any factor
O Recommendation
O It is still needed to be implemented on another rotohead due
to time limitation