Quality Improvement Analysis of X Brand Tube Packaging Using Six Sigma and Failure Mode and Effects Analysis (FMEA)
DOI:
https://doi.org/10.33479/sakti.v5i02.167Keywords:
Six Sigma, Failure Mode and Effect Analysis, Tube Packaging, Sigma Level, quality controlAbstract
PT XYZ is a manufacturing company producing cosmetic products, including 180 ml lotion packaged in tubes. From January to July 2024, the average defect rate reached 0.82%, exceeding the company’s maximum tolerance limit of 0.8%. This study aims to evaluate the sigma level, identify the root causes of defects, and propose improvement strategies to enhance packaging quality. The research applies the Six Sigma methodology integrated with Failure Mode and Effects Analysis (FMEA) using the DMAIC (Define, Measure, Analyze, Improve, Control) framework. The results identify four dominant defect types: unsealed sealing, damaged caps, damaged batch codes, and dented containers. The initial sigma level of 3.27 indicates suboptimal process performance. Based on the FMEA results, the main causes of defects include worn machine components and the absence of standardized work instructions. Improvement actions proposed and implemented include replacing critical machine parts, adjusting machine operating parameters, and installing a leakage tester. Following the implementation of these improvements, the sigma level increased to 4.30, and the average defect rate decreased by 96.65%, demonstrating a significant enhancement in the quality of the tube packaging process.
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