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 Clip sandals and Lightspeed Cross Bar sandals. The problem that occurs is thatthere is one sandal product with the highest level of disability, namely the Eiger LightspeedClipbar sandal product which reaches 9,101% per year. The purpose of this study was toidentify the type of defect in the Lightspeed Clipbar sandal product through the DMAICstages (Define, Measure, Analyze, Improve, and Control)) and make a proposedimprovement in the assembling and buffing process at PT X. Based on the results of thestudy, identified factors causing defects between Other: open bonding, the sides of thesandals are not neat and the erosion of the Lightspeed Clip logo sandals. Factors that causesandals 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 sigmavalue does not meet the sigma process capability standards for industries in developedcountries, which is 5-6 sigma. While the results of the Taguchi experimental calculations thevalue of the average quality characteristics for sandals defects amounted to 3.40 to 0.32 andthe S / N quality characteristics of 10.67 to 0.24. The conclusion of this study resulted incorrective action on the Eiger Lightspeed Clipbar sandals product, which is obtained theoptimal level setting of factors that affect the defects of Eiger Lightspeed Clipbar sandals,including the 28g glue factor, 15 mm rubber soles and 13 mm benzene. Confirmation resultswith an optimal setting level obtained values of 3.31 to 0.38, as well as S / N qualitycharacteristics for the defects of the Lightspeed Clipbar sandals 10.54 to 0.