QUALITY IMPROVEMENT OF CEMENT BAGS USING LEAN SIX SIGMA METHODOLOGY (CASE STUDY: THE BAG PLANT OF PT SEMEN PADANG)

Ghina, Salsabilla Amnedya (2021) QUALITY IMPROVEMENT OF CEMENT BAGS USING LEAN SIX SIGMA METHODOLOGY (CASE STUDY: THE BAG PLANT OF PT SEMEN PADANG). Diploma thesis, Universitas Andalas.

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Abstract

Cement sales in Indonesia have been rising due to several factors such as the government’s immense infrastructure agenda which includes the construction of thousands of kilometers of road, dozens of airports, property industry, buildings, and so forth. This leads to more performers in the cement industry joining the marketplace and as the result, the market competitiveness becomes more intense. Therefore, in order to survive in the competitive market growth, improving product quality and production process productivity is an essential key for every company. This study is aimed to identify the types of defects that occur within the production process of cement bags in the Bag Plant of PT Semen Padang, determine the underlying causes of the defects, and propose improvement solutions. Within the field of quality improvement, Lean Six Sigma has become one of the most proven methodologies. Therefore, this research is carried out using the DMAIC methodology. The business process of the Bag Plant is illustrated using the SIPOC Diagram. The critical qualities for a cement bag are described using a CTQ Tree and the production process of the cement bag is described using the Flow Process Chart. The proportion between the defective product and the total production is measured using a P-Chart. To identify the sigma level of the production process, the DPMO calculation has been firstly calculated. Thereafter, the capability of the production machines is measured using the OEE calculation. The possible root causes for each defect type are identified using the Cause and Effect Diagram. The result shows that the production process’ sigma level is 3.81 where it can be illustrated that there are 10,326 defective products within 1 million productions and the average OEE rate is 41% where it is categorized as low. There are six types of defects found in cement bag products. These defects occur due to various causes such as machines problem, poor quality of raw materials, methods variations, the negligence of personnel, unideal environmental conditions, and managerial concerns. By means of the improvement solutions, it is highly recommended to group and count the defective products based on their defect types, create a control sheet for definite defects, upgrade the report documents, and set up some measuring instruments in the storage. An upgraded version of the daily production record is proposed with the purpose of assisting the Control phase.

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