APPLICATION OF DMAIC AND TAGUCHI METHODS TO MINIMIZE THE DEFECTIVE PRODUCTS FLIP LIGHTSPEED CLIPBAR

PT X is an industrial company that produces sandals including Lightspeed Clipbar, Lightspeed Clipsandals and Lightspeed Cross Bar sandals. The problem that occurs is that there is one sandalproduct with the highest level of disability, namely the Eiger Lightspeed Clipbar sandal productwhich reaches 9,101% per year. The purpose of this study was to identify the type of defect in theLightspeed Clipbar sandal product through the DMAIC stages (Define, Measure, Analyze, Improve,and Control)) and make a proposed improvement in the assembling and buffing process at PT X.Based on the results of the study, identified factors causing defects between Other: open bonding, thesides of the sandals are not neat and the erosion of the Lightspeed Clip logo sandals. Factors thatcause sandals are defects, glue, soles and benzene. The DPMO (Defect per Million Opportunities)value of the DMAIC results is 30376.12 with an average sigma score of 3.38. The sigma value doesnot meet the sigma process capability standards for industries in developed countries, which is 5-6sigma. While the results of the Taguchi experimental calculations the value of the average qualitycharacteristics for sandals defects amounted to 3.40 to 0.32 and the S / N quality characteristics of10.67 to 0.24. The conclusion of this study resulted in corrective action on the Eiger LightspeedClipbar sandals product, which is obtained the optimal level setting of factors that affect the defectsof Eiger Lightspeed Clipbar sandals, including the 28g glue factor, 15 mm rubber soles and 13 mmbenzene. Confirmation results with an optimal setting level obtained values of 3.31 to 0.38, as wellas S / N quality characteristics for the defects of the Lightspeed Clipbar sandals 10.54 to 0.