SIX SIGMA YELLOW BELT

Victory Team Rapid 4

2022
Victory
Team Project Sponsor Mentor

Rahman Susilo Yunanta Cahyo

W. & Prod.
Engineering
Departement Head
Plant Manager

Team Leader Team Member Team Member Team Member Team Member
Lendy Setyawan Bahruji Evi Damayanti Hery Nur C. Andre Okta
Technician Prod Inspector QA Admin Prod Technician Prod Technician Prod
 Step Project Overview

Increasing Production Efficiency Less Internal Reject

D M A I C
DEFINE MEASURE ANALYZE IMPROVEMENT CONTROL
Background CTQ MSA Improvement plan DPMO (After
Project Title Pareto Diagram SPC Mistake Proofing Improvement)
Problem Statement (current data) Fishbone Diagram . Control Plan
Goal Statement DPMO (Before Why why Analysis
Project Timeline improvement) FMEA
SIPOC
DECREASE INTERNAL REJECT
INDOMILK 190ML BOTTLE
Project Charter
01 Project Title
DECREASE INTERNAL REJECT INDOMILK 190ML BOTTLE

02 Problem Statement
There is 1.61% Internal Reject (Sigma Level 4.4)
in Indomilk 190ml Bottle Product in the Uniloy UR-90 Machine
on October 2021 - January 2022

03 Goal Statement
Reduce Internal Reject in Indomilk 190ml Bottle with target
Internal Reject 1.1% on August 2022 (Sigma Level 4.5 )
 Background
Sales Order
% Utilization % Internal Reject
14,000,000

12,000,000
100 92
87.54 86.53 3
85.62 2.47
77.36 74.49 2.5 10,000,000
80 67.87 1.96
55.56 2
60 8,000,000
1.5 1.36
40 6,000,000
1 0.66 0.67 0.71 0.77
0.48
20 0.5 4,000,000

0 0 2,000,000
Oct Nov Dec Jan Oct Nov Dec Jan
0
ar
y
ar
y ch ril ay ne ly st er er be
r
be
r
nu ru ar Ap M Ju Ju ugu mb ob
ct em cem
Ja Feb M A pt
e O ov
BM IM BM IM Se N D
e

Good Utilization, but High Internal Reject too. High Sales Order Enough, but Customer Complaint too.
In October 2021 to January 2022, Indomilk bottles have a good At the end of 2021, the sales of Indomilk bottles were quite high, but
utilization, but in that month they also have high internal rejects. there were complaints from customer regarding quality problem such as
And it causes the internal reject target is not achieved (target foreign material contamination.
0.7%).

Indomilk 190ml Bottle Machine Uniloy UR90

Single Supplier PT. Indolakto Pandaan High speed Blow molding machine
 Timeline Project
MONTH-2022
NO STEP
MARCH APRIL MAY JUNE JULY AUGUST SEP OCT
Plan
1. DEFINE
Actual
Plan
2. MEASURE
Actual
2018 2019 2020 2021 2022
Plan
3. ANALYZE
Actual
Plan
4. IMPROVE
Actual
Plan
5. CONTROL
Actual

Plan Actual
 SIPOC DIAGRAM
SUPPLIER INPUTS PROCESS OUTPUTS CUSTOMERS

RAW MATERIAL PO RAW MATERIAL INCOMING RAW STOCK MATERIAL HDPE WAREHOUSE RAW
HDPE MARLEX EHM MARLEX EHM 6007
SUPPLIER MATERIAL MATERIAL
6007 NATURAL NATURAL

WAREHOUSE RAW GOOD MOVEMENT DELIVERY TO MATERIAL

PRODUCTION MATERIAL IN THE SACK
MATERIAL SLIP PRODUCTION TEAM
DEPARTMENT

MATERIAL MATERIAL IS POURED READY TO USE PRODUCTION

MATERIAL IN THE SACK IN SILO AND MIXING
PRODUCTION TEAM MATERIAL DEPARTMENT
WITH AFVAL

PRODUCTION READY TO USE BLOW MOULDING

INDOMILK BOTTLE QA
DEPARTMENT MATERIAL PROCESS

QA INDOMILK BOTTLE QUALITY CHECKING PRODUCT RELEASE WAREHOUSE

CUSTOMER
WAREHOUSE INDOMILK 190ML BTL DELIVERY TO GOOD QUALITY PT INDOLAKTO
CUSTOMER PRODUCT
PANDAAN
CRITICAL TO QUALITY

Customer
Satisfaction
Your Text Here
You can simply impress your audience and add a
unique zing and appeal to your Presentations.
Product Quality

Your Text Here

You can simply impress your audience and add a
Appearance Dimensional
unique zing and appeal to your Presentations.

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BLA DEN EIG BAD Your Text Here

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You can simply impress your audience and add a
unique zing and appeal to your Presentations.

CK TED BUB N FLA CUT WEI

MEL
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You can simply impress your audience and add a
unique zing and appeal to your Presentations.

T TLE ERI G T
AL
DPMO & SIGMA LEVEL
TOTAL OF REJECT PRODUCT (PCS)
Pareto Diagram CTQ
TOTAL
TOTAL OF GOOD
PRODUCT (PCS)
Frequency Accumulation Frequency (PCS)
OCT 2021 NOV 2021 DEC 2021 JAN 2022 OCT 2021 - JAN 2022

99.277% 99.999% 100% 100% 100% 100% 100% Black Spot 96,855 205,416 52,045 99,740 454,056
500,000 100%
Dented Bottle 30,000 50,045 19,943 33,596 133,584
454,056
450,000 90% Bubble 3,753 524 4,277
Foreign Material 3 3
400,000 80%
76.709% Flash 0
37,586,400
350,000 70% Unmelted 0
Bad Cutting 0
300,000 60%
Weight O.O.S 0
250,000 50% Total Reject 130,608 255,464 72,512 133,336 591,920
% Reject 1.36% 2.47% 0.67% 1.96% 1.61%
×CTQ= Total Reject Pro
200,000 40%
Opportunity=Total Product DPU
150,000 133,584 30% Opportunit
¿ 38,178,320 × 8 591,920
100,000 20% ¿
305,426,56
50,000 10% ¿ 305,426,560
4,277 3 0 0 0 0
¿ 0.00193
0 0%
t e l .
po ttl bl
e
ri a sh d ng .S
ac
k
S
ed
Bo Bu
b
M
at
e Fl
a
nm
e lte
C
ut
ti
h tO
.O DPMO= DPU × 1,000,000
d
Bl nt gn U
Ba ig
D
e
Fo re
i
W
e
¿ 0.001938 × 1,000,000
¿ 𝟏 , 𝟗𝟑𝟖
SIGMA LEVEL = 4,4
DPMO Target Opportunity = Total Product x CTQ
= 38,178,320 x 8
= 305,426,560

DPU = Total Reject Product

Opportunity
= 591,920
Before
2500 305,426,560
= 0.001938
2000 Sigma DPMO = DPU x 1,000,000
1938
1500 Level 4.4 = 0.001938 x 1,000,000
1430 = 1,938
Pcs

1000

500

0
DPMO 4.8
4.7
Before Target 4.6
4.5
4.5
4.4

Pcs
4.4
4.3

Target Sigma 4.2

4.1

Maximum of reject is 1.14% Level 4.5 4

LEVEL SIGMA

Target Before Target

 MSA VARIABLE - WEIGHT

MSA Variable - Weight

MSA was carried out by 3 appraiser that used 10 product samples
Repeatibility - Reproducibility - with 2 trials.
Equipment Appariser Variation
Variation

Summary
% GRR : 12,96% → CONSIDERED, This result explains that the
% EV = 8.46% % AV = 9.81%
measurement system may be acceptable (relatively good), depending
on the importance of its application.

Repeatibility - Summary
Number of Distinc Ndc : 10,79 → This result explains that the system is acceptable and
Reproducibility
Categories can be distinguished between parts.

% GRR = 12.96% Ndc = 10.79 Summary

AV > EV ; The AV value greater than the EV indicates that all
operators must be trained to use the measurement tools.
 MSA VARIABLE - WEIGHT
MSA Variable - Weight
Second MSA (Retrained) MSA was carried out by 3 appraiser that used 10 product samples with 2 trials.

Summary % GRR = 12.96%

Repeatibility - Reproducibility % GRR : 6.36% → ACCEPTED, This result explains that the
measurement system is OK (very good). % GRR = 6.36%

Summary Ndc = 10.79

Number of Distinc Categories Ndc : 22.13 → This result explains that the system is acceptable
and can be distinguished between parts. Ndc = 22.13

Repeatibility - Equipment Summary % EV = 8.46%

Variation
EV > AV ; The EV value greater than the AV indicates % EV = 6.16%
that all operators can operate and read the tool, also
the tool must be calibrated.
Reproducibility - Appariser % AV = 9.81%
Variation In here, Tool calibration is carried out once a year
% AV = 1.56%
 MSA ATTRIBUTE
Date May, 19th 2022
MSA Attribute
Product Indomilk bottle 190ml #Appraiser 3
Characteristic/ Parameter Observerd Appearence #Part 15 Appearance
Score Type Pass or Fail Replication 80% 2
MSA was carried out by 3 appraiser that used to 15 product samples
with 2 trials.

► Calculation Results
Appraiser Susanto Fahrozi Anam
Summary Summary
Agreement Score
02
86,7% 73,3% 55%
73,3%
Within Appraiser
01
Agrement Score The agreement score between
each Appraiser vs 86,7% 66,7% 53,3% The agreement score between appraiser vs standart is 40% 
Standard appraiser is 46.7%  this result this result explains that the
measurement system has not
explains that the appraiser guaranteed consistent and
needs to be retrained. standardized measurement
Agreement Score Between Appraiser 46,7%
results.
Agreement Score All Appraiser vs
40%
standard
 MSA ATTRIBUTE
Second MSA Attribute (Retrained)
Date July, 25th 2022
Product Indomilk bottle 190ml #Appraiser 3
Characteristic/ Parameter Observerd Appearence #Part 15
Agreement Score Within Appraiser
Score Type Pass or Fail Replication 2
This result explains that the score of Susanto and
Fahrozi is highter than Anam.
► Calculation Results
Appraiser Susanto Fahrozi Anam Agrement Score each Appraiser vs Standard
This result explains that the highest score of all
Agreement Score appraisers is Fahrozi.
100% 100% 93,3%
Within Appraiser

Agrement Score Agreement Score Between Appraiser

each Appraiser vs 93,3% 100% 93,3%
Standard This result explains that all appraisers have the
same agreement in some measurements.

Agreement Score Between Appraiser 93,3%

Agreement Score All Appraiser vs standard
Agreement Score All Appraiser vs This result explains that all appraisers have the
93,3%
standard
same agreement in some measurements and the
results are in accordance with the standard.
 SPC of Weight (11.5 - 13.5 gr)
This control chart is based on weighing the product on May, 2022. Samples were taken 6 times and each sample collection
was 8 PCs

Xbar Chart - Weight of Bottles R Chart - Weight of Bottles

12.20 0.7
12.18 0.6
12.16 0.6
12.14
12.12 12.1 UCL; 12.1 0.5 UCL; 0.5
12.10
0.4
12.08

Avg (gr)
Avg (gr)

0.4
12.06
12.04 CL; 12.04
0.3 CL; 0.29
12.02 12.0 12.0 12.0 12.0 12.0
12.00 0.2 0.2
11.98 0.2
11.96 LCL; 11.96 0.1 0.1
11.94 0.1 LCL; 0.1
11.92
11.90 0.0
1 2 3 4 5 6 1 2 3 4 5 6

Taken Sample Taken Sample

Xbar Chart Before Improvement

Based on that chart, we can conclude that the process
is stable, even though in the range chart, there is one of
the value is out of control.
Cpk = 1.55
This result explains that the process is good, if there will be increasing variation in
the future, less opportunity deviate from the specification.
FISHBONE DIAGRAM

ENVIRONMENT MATERIAL MACHINE

Dirty Room Conditions Material Contamination Extruder Encrustation

BLACK
SPOTS

Missed check for barrel crust Heating up barrel

at the tail bottom of bottle too long

MAN METHOD
 Why Why Analysis
Defect Factor Problem Why Why Why Verification Data Root Cause

Scorched material
Scorched material Heating up barrel To reach a more
Machine Extruder encrustation caused by too long
on the barrel too long melting point
heating up the barrel

Machine maker's
Based on
Heating up barrel too To reach a more instructions for screw
Method Machine Maker’s Safety Screw
long melting point safety make the heating
instruction
up barrel longer

The surface of sacks

Black Spot The surface of sacks material is not cleaned
Material There are particle The surface of sacks
Material material is not first can cause dust
contamination of dust on material material was dirty
cleaned first contamination of the
material

Tail bottom that was The operator is not

Focus on bottles
crushed into regrind The operator is too thorough in checking,
Operator was not that will be packaged
Man contaminated with focused on the bottle especially at start up
careful into finished
barrel encrustation only after the machine has
good products
missed checking been off for too long

Operator doesn’t
The operator is Operator doesn’t implement SOP and WI
Dirty room Production area
Environment inconsistent in implement SOP properly causes
conditions not clean enough
cleaning the area and WI properly production area not
clean enough
FISHBONE DIAGRAM

ENVIRONMENT MATERIAL MACHINE

Jammed Detaber

DENTED
BOTTLE

MAN METHOD
 Why Why Analysis

Verification
Defect Factor Problem Why Why Why Root Cause
Data

Broken needle blow

Dented Needle blow causes Unblow and
Machine Jammed On Detaber Unblow Porison Lifetime
Bottle is broken makes the bottle
jammed on the conveyor
Failure Mode and Effects Analysis
Current

Occurrence

Occurrence
Responsible

Detection
Detection

Severity
Severity
Process Process
Failure Failure Potential Failure Current Process & Target
Step / Requirements C Control RPN Recommended Actions Actions Taken RPN
Mode Effect Cause Control (Prevention) Completion
Function (Detectio
Date
n)

Setting
Purging material at Check the condition of
Reduce black Burnt Heating up too Visual Prod. temperature
Start Up Black spot 7 Critical 6 least 10 shots before 7 294 porison before start up 7 5 5 175
spots material long Check Aug 2022 barrel between
running production the machine
180°c - 200°c

Regrind
contaminated with
crust and have
Inconsistent Separating bottles and
Tail bottom that crushing Check the
in checking There is a checker tails that contaminated
Checking contaminated processed will Visual Prod. condition of
the Product with crust does
the tail Black Spot 7 Critical 5 who checking the tail 5 175 for cutting process 7 4 4 96
make dark spots Check Aug 2022 regrind before
bottom of bottom of the bottle (prying) before
not crush worse due to used
the bottle crushing
using the close-
loop material
system

Dented
Check the condition of Polish the tip of
bottles
Cutting tail Needle blow in Porison needle blow in bad Check the condition of Visual the needle blow every Eng. & Prod. the needle or
occur due 5 Major 4 4 80 5 3 3 45
process good condition unblow condition Neddle blow Check week and clean it Aug 2022 replace it with a
to jam from
before start up new part
Detaber
Improvement Plan
What
Factor Why Where How When Who How Much
Problem Failure Effect

To reach a perfect melting Reduce heating up

Method Heating up too long Crusty barrels point and keep the screw safe Machine parts July 2022 Prod. -
to avoid breakage duration

Barrel Temperature Materials burned when Setting temperature barrel

overheat heating up machine For safety screw Machine parts July 2022 Prod. -
between 180°c - 200°c
Machine
Polish the tip of the
Unblow caused by broken
Jammed on detaber Dented bottle Mold parts needle or Needle blow August 2022 Prod. & Eng. USD 119.46
needle blow
replacement
The tail of the bottle that
Uneven understanding contaminated
of operator when encrustation also The operator is too Training operator about
Man focused on the bottle Production Area quality checking when August 2022 Prod. -
checking bottle at start processed in the crusher
only start up machine
up machine and it will
contaminate regrind

The procedure for pouring

Dust-contaminated The surface of sacks material is material into the silo is
Material material Black Spot not cleaned first Production Area carried out according to July 2022 Prod. -
Work Instruction

The production area is not Cleaning area only carried out Cleaning production area
clean enough and dust by the Cleaning Service in the
Environment Dirty room condition Production Area every shift also by the August 2022 Prod. -
may contaminate morning operator.
materials and products.
Improvement
No Root Cause Action Plan Before After PIC

Machine
1 Heating Up Barrel too long Reduce heating up duration. Heating up process for 2 hours Heating up process to 1.5 hour
Operator

The surface of sacks material is not Clean all of the surface of sacks with canebo
2 MPC Operator
cleaned according to Work Instruction.

At the beginning of start up there was an

Missed check for barrel crust at the operator who checked the part of tail bottom Packaging
3 N/A
tail that was contamined with crust and separated Operator
it.

Cleaning production area in the morning by

Packaging
4 Dirty room condition cleaning sevice and every shift also by the
Operator
operator.

Broken needle blow causes Unblow

Polish the damaged needle blow tip and Machine
5 and makes the bottle jammed on
replace the badly damaged needle blow. Operator
the conveyor.
broken needle blow tip
 SPC of Weight (11.5 - 13.5 gr) Xbar Chart - Weight of Bottles
12.30
12.26
12.22
UCL; 12.2
12.18
12.14 12.12 12.12
12.11 12.11

Avg (gr)
Xbar Chart - Weight of Bottles 12.11 12.10
CL; 12.11
12.10
12.30
12.06
12.26
UCL; 12.2 12.02 LCL; 12.01
12.22
11.98
12.18
Xbar Chart - Weight of Bottles 12.15 12.14 12.14 12.14 12.14 11.94
12.14 12.12 CL; 12.14

Avg (gr)
12.30 11.90
12.10 1 2 3 4 5 6
12.26
12.06 Taken Sample
12.22
12.02 LCL; 12.03
12.18
11.98
12.14
Avg (gr)

12.1 UCL; 12.1

11.94 AFTER IMPROVEMENT (September 2022)
12.10
11.90
1 2 3 4 5 6 Cpk = 1.68
12.06
CL; 12.04 Taken Sample
12.02 12.0 12.0 12.0 12.0 12.0

11.98
LCL; 11.96
11.94 cpk value
11.90
DURING IMPROVEMENT (August 2022)
1 2 3 4 5 6
Cpk = 1.56 1.7 1.68
Taken Sample 1.65

1.6
1.55 1.56
1.55
BEFORE IMPROVEMENT (May 2022)
Cpk = 1.55 1.5
Based on those charts and the value of 1.45
process capability, we can conclude that Before During After

the process is stable and better. Cpk

Production Data : August 2022
DPMO After
CTQ
TOTAL REJECT
(PCS)
%
TOTAL OF GOOD
PRODUCT (PCS) Improvement
Black Spot 22,860 35.26%

Dented
Opportunity = Total Product x CTQ
Bottle
41,976 64.74% % Reject = 10,218,636 x 8
100% = 81,749,088
Bubble 0 0% 90%
80% DPU = Total Reject Product
Foreign 70% Opportunity
Material
0 0% 60%
= 64,836
50%
Place Your Picture Here 40%
Flash 0 0% 81,749,088
30%
10,153,800 20% = 0.0009642
Unmelted 0 0% 10% DPMO = DPU x 1,000,000
0%
ts e le l . = 0.000793 x 1,000,000
Bad o ttl ia sh te
d
tin
g .S
0 0% Sp Bo bb er Fl
a el ut .O = 793
Bu at m C tO
Cutting ck te
d M n
a n U d gh
Bl e n ig Ba ei
D re W
Weight Fo
O.O.S
0 0%
Before Improvement August
Total
Reject
64,836
SIGMA LEVEL = 4.6
% Reject 0.63%
Control Plan
Charateristic Metods
Part / Process Name / Machine, Device, Sample
Process Operation Desc. Jig, Tools for Mfg Evaluation Control Method Reaction Plan PIC
No. No Product Process Product / Process Spec / Measurement
Tolerance Technique Size Freq.

1 Incoming Raw Receipt 1 Resin HDPE Marlex Batch No., Material item, 1 plastic bag @25 kg Visual 50 gr Per Batch Inspection Report OK / Not OK Incoming
Material Total Material Inspector

1 Temperature Barrel 166 - 201 (°c) Thermometer 1x Per day Checklist Inform to
Parameter Setting machine setter
Machine
technician

Checklist Inform to Machine

2 Air Pressure 6 - 8 (bar) Pressure Gauge 1x Per day Parameter Setting machine setter technician

3 Temperature Chiller mold 12 ± 3 (°c) Thermometer 1x Per day Checklist Inform to

Parameter Setting machine setter
Machine
technician

2 Blow Process Uniloy UR90 4 as per specification Temperature feedthroat 30 ± 11 (°c) Thermometer 1x Per day Checklist Inform to Machine
Parameter Setting machine setter technician

5 Pressure chiller mold 75 ± 5 (Psi) Pressure Gauge 1x Per day Checklist Inform to
Parameter Setting machine setter
Machine
technician
Preventive
6 Flow Chiller Mold (minimum) 130 gpm Flowmeter 1x Per day maintenance Inform to Machine
checklist machine setter technician

Temperature Chiller for Checklist Inform to Machine

7 cooling machine 12 ± 1 (°c) Thermometer 1x Per day Parameter Setting machine setter technician
Control
Cost of Poor Quality

COPQ (USD) Reject (Pcs)

70000
$1,253.71 64,836

60000

50000
$830.97 40,564
$769.93 38,880
$711.41 40000 36,912

30000

20000

10000

0
July August September October
July August September October

From those charts we can conclude that in the last 4 months the
number of production rejects is decreased,
which means the cost of poor quality also getting smaller.
 % Internal Reject
2.7
2.4
2.1

Sigma Level
1.8
1.5
1.2 2.47

%
1.14
1.96

Realization
0.9
0.6 1.36

0.3 0.67 0.72 0.54 0.63

0.47 0.46 0.53 0.53 0.44 0.42
0
Oct-21 Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul-22 Aug- Sep- Oct-22
21 21 22 22 22 22 22 22 22 22

Before After Target

Internal Reject

Sigma Level
Based on that chart, We can conclude that the internal reject
target was achieved with a decrease in internal reject to 0.63%,
4.6 4.6 which is equal to the Sigma 4.6 level in August 2022.
4.55

4.5 4.5
Saving
4.45 Saving Material
Electricity Cost
4.4 4.4
After Improvement, we can After improvement, we can save
4.35 save electricity costs by 48 kWh material cost as much as 4,928.7 kg
or equivalent to USD 3.16 every or equivalent to USD 5,660.5
4.3 heating up machine.
Before Target After
THANK YOU
PT RAPID PLAST INDONESIA PLANT 4