JURNAL ILMIAH TEKNIK INDUSTRI

ISSN: 1412-6869 (Print), ISSN: 2460-4038 (Online)

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doi:10.23917/jiti.v20i1.12443

Quality Control on Minimizing Defect Product on 20 OE

Yarn
Arinda Soraya Putri1a, Fitdhan Primananda1
Abstract. Industrial businesses in Indonesia realize that consumer desires have changed over time. Consumers
desire that becomes the main priority is quality. PT. Bitrate Industries, as a company that produces yarn in Semarang,
always strives to improve product quality to the desires of consumers. The company faces quality control problems:
the production process of 20 OE yarn, producing the highest defective products. The Six Sigma approach analyzes
the causes of defects, identifies sources of variation, proposes improvements with 5W + 1H, and implements a
quality control plan. Most defects occur in the production process in the autocross engine, which is caused by engine
wear. Implementation of the kaizen approach can be given proposals in the form of improvements in maintenance,
according to the existing scheduling and periodic replacement of parts. This study concludes that the proportion of
defects is still in the controlled stage, but the quality control of the product is still needed. A quality improvement
project with a Six Sigma approach can benefit any company that needs to find the most efficient way to improve
product quality.

Keywords: Six Sigma, Kaizen, 5W+1 H, Quality Control, 20 OE Yarn.

According to Sukardi et al. (2011), quality

I. INTRODUCTION 1 improvement in the production process must be
carried out continuously to minimize product
At this time, industrial business players in defects. The commitment of the company to
Indonesia realize that consumer desires have continue to maintain high quality is by
changed over time. Consument desires, the top implementing various good management
priority is quality, both in service and the systems, more effective production systems, and
products produced. In the industrial world, trying to minimize the possibility of products not
competition intensifies, companies must survive conforming to predetermined specifications
and compete with similar companies. Consumers (product defects). PT. XXX Industries is a company
have put pressure on the industry for the that produces yarn in Semarang, which always
products they purchase to have a higher value. strives to improve product quality towards
The industry which adopts various quality consumer desires in each of its production. This
management tools and concepts drives better Factory produces open-end yarn, TC yarn, PC
product quality with lower costs. This adoption yarn, CVC yarn, and Modal Cotton yarn for single
leads to the adaptation of different quality and TFO yarn for double yarn.
management concepts into the company's Quality is conformance to requirements,
production (Joshua Chan Ren Jie et al., 2014). In which is following the requirements or standards.
addition to emphasizing the products produced, A product has quality if it conforms to
it is necessary to give more attention to the predetermined quality standards. Quality
quality in the production process (Ariani, 2003). standards include raw materials, production
processes, and finished products (Crosby, 1979). It
1 is best if the attention to quality is not on the final
1 Industrial Engineering Department, Faculty of product, but on the production process or
Engineering, Universitas Muhammadiyah Surakarta, Jln. products that are still in the process (work in
Ahmad Yani, Kartasura, Sukoharjo 53162, Indonesia
process), so that if it is known that there is a
a email: asp835@[Link] defect or error, it can still be corrected. Thus, the

corresponding author final product produced is defect-free, and there is
no more waste of time and cost that must be paid
Submited: 20-12-2020 Revised: 20-05-2021
dearly because the product must be discarded or
Accepted: 07-06-2021
1
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Putri & Primananda/ Quality Control on Minimizing Defect Product …. JITI, Vol.20(1), Juni 2021, 81-88

reworked. This quality can be achieved by main benefits of implementing Six Sigma include
determining applicable methods, including increased profit and financial savings, increased
statistical techniques and others (Gaspersz, 2003). customer satisfaction, reduced costs, reduced
To produce a good quality product, the variations cycle times, improved vital performance metrics,
that occur must be minimized. Solve the problem reduced defects, reduced machine downtime,
of product defects, and not all causes can be reduced inventory, improved quality, and
resolved at once. The company must be able to increased production capacity. However, this
identify what issues need to be prioritized first. must be balanced with individual abilities because
Therefore, we need a method to overcome these Six Sigma is only a tool, and the people
problems (Shanty, 2012). implement it (Muraliraj et al., 2017). Six Sigma can
One method can control quality and measure industrial systems' performance to make
overcome the number of defects in the six sigma tremendous improvements with actual strategic
method (Assarlind et al., 2012). In statistical terms, breakthroughs. The higher the sigma target
Six Sigma means 3.4 defects per million achieved, the better the industrial system
opportunities. Sigma is the standard deviation of performance is. Therefore, this study uses the six
data in statistics. In addition, sigma is a measure sigma approach and 5W + 1H to determine
of variability which illustrates that the data is still quality control in the yarn production process and
in the statistical distribution of the mean suggest improvements.
(average) value. Six Sigma's goal is to unify all
operations across manufacturing steps to II. RESEARCH METHOD
produce the desired results. It is a disciplined and
structured approach that focuses on constantly The location of this research was conducted
providing the perfect product or service to at PT. Bitrate Industries, Semarang from 5 August
customers (Akhil Khajuria et al., 2018). Dewi to 31 August 2019. The following are the stages
(2012) has proven that by applying this method of data analysis using the six sigma method and
to make quality improvements in the yarn 5W + 1H.
manufacturing industry.
Dewi (2012) states that the six sigma concept Define Stage
is a continuous improvement to reduce defects Define is the first stage in the concept or
by minimizing variations in the production program for improving the quality of the Six
process. Although Six Sigma originated in Sigma method. The first operational step that will
manufacturing in the late 1980s, this concept has be carried out is to determine the goals and
been successfully applied in a wide variety of objectives of quality improvement and identify
fields, including healthcare, information product defects. Before defining the key
technology, distribution operations, healthcare, processes and customers in a Six Sigma project,
supply chain management, inventory knowing the SIPOC process model (Supplier,
management, education, construction, Input, Process, Input, and Customer) is necessary.
warehouse, etc. to improve processes and to
Measurement Stage
correct inefficiencies (Mazen Arafeh et al., 2017).
The measure is the second stage in the six
According to Vanany and Emilasari (2007),
sigma method. This measurement stage is carried
the six sigma quality improvement
out in 2 stages, namely: determining the
implementation stages consist of five phases,
proportion of the most dominant defects that will
namely defining, measuring, analyzing, improving,
qualify as CTQ (Critical to Quality) using the
and controlling (DMAIC). 5 why, cause and effect,
Pareto diagram, and then calculate the process
Pareto analysis, change management tools,
capability (sigma) and DPMO (Defects Per Million
histograms, control charts and scatter diagrams
Opportunities). This sigma capability
are a common set of tools that can be used
measurement is carried out to determine the
interactively between Lean and Six Sigma. The
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process capability of the identified defect the 5W + 1H tool. Five Ws and one H are used
products. widely as management tools in a variety of
environments. Five Ws and one H, namely Who,
Analyze Stage What, Where, When, Why, and How. The fourth,
After obtaining data at the define stage and the five m checklist, focuses on the five critical
measure stage, the third stage identifies the factors involved in each process: man, machine,
causes of quality problems. This stage can be material, methods, and measurement. In each
done using the p control chart (P-Chart), process, improvement can be made by examining
determining whether products are outside the aspects of the process.
control limit.
III. RESULT AND DISCUSSION
Improve stage
This stage is the stage of improving the Define Stage
process and eliminating the causes of the defect. At this stage, determine the goals and
The steps to carry out quality improvement can objectives of improvement. The object of this
use Kaizen implementation tools, including Kaizen research is 20 OE (open end) threads because this
Five-Step Plan, Five W, One H, and Five-M product is a product that is produced for a whole
Checklist. month in July 2019. From the standard
specifications set by PT. Bitrate is still found
Control stage products that have defects or, in other words, do
This stage is the last operational stage in a six not meet the quality standards that have been
sigma quality improvement project. At this stage, set. Defects in 20 OE threads include (crossing,
the results of quality improvement are breaking, dirty, hard rolls, loose rolls, bad rolls, ex
disseminated, successful best practices in yarn, broken cheese, over doffing, underweight,
improving the process are standardized and lapping).
made standard work guidelines, and ownership or
responsibility for the process, which means that Measure Stage
six sigma ends at this stage. At the measuring stage, identify potential
Critical to Quality (CTQ) that affects product
Kaizen Implementation Tool quality from predetermined specification
Kaizen is a term in Japanese for the concept standards. CTQ is a measurable characteristic of a
of Continuous Incremental Improvement. Kai product or process that must reach the standard
means change, and Zen means good. Kaizen or limit of the specification. The number of 20 OE
means a continuous good change that involves yarn production in July 2019 was 10,669 cones
everyone. This approach only works well when with defects of 1,061 cones. Pareto diagram
accompanied by the right human resource effort making is used to determine the most dominant
because people are the most critical dimension in defect, which will later be identified as CTQ so
improving quality and productivity. There are four that you can find out the type of defect that must
kaizen implementation tools. The first kaizen be repaired immediately. The results of the Pareto
checklist, which is to identify problems that can diagram can be seen in Figure 1.
describe opportunities for improvement, is to use The diagram shows the types of defects that
a checklist of factors that are likely to need often occur or identify the CTQ sequence with the
improvement. Second, namely, the kaizen five- details of the defect over doffing as many as 582
step plan, which is the approach used by cones, less weight as much as 156 cones and bad
Japanese companies. This step is often called the rolls as many as 98 cones. Attribute data is often
5-S movement, which is the initials of Japanese in the form of categories or classifications such as
words: Seiri, Seiton, Seiso, Seketsu, and Shitsuke. good or bad, success or failure, and so on. The
Third, the implementation of Kaizen is done using number of Defects can be used as a table

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Pareto Diagram
600
500
400
300
200
100
0

Figure 1. Pareto Diagram

Table 1. Potential CTQ Sequences

Number of Cumulative
No Type of Defect Cumulative Defects Percentage (%)
Defects Percentage (%)
1 Over doffing 582 582 54.85 54.85
2 Less Weight 156 738 14.70 69.56
3 Poor Roll 98 836 9.24 78.79
4 Deflated Roll 60 896 5.66 84.45
5 Tight Rolls 47 943 4.43 88.88
6 Lapping 44 987 4.15 93.03
7 Broken Paper Cone 24 1011 2.26 95.29
8 Dirty 20 1031 1.89 97.17
9 Crossing 16 1047 1.51 98.68
10 Disconnect 8 1055 0.75 99.43
11 Ex Yarn 6 1061 0.57 100.00

according to the CTQ potential with the highest threads following the specifications set by the
defect. Potential CTQ sequences can be seen in company. This is still far from the expectation of
Table 1. realizing zero failure. However, it is still included
The next step is to calculate the DPMO value, in the efforts to improve quality towards zero
which will later be converted into the sigma value defects to provide total satisfaction to customers.
capability. DPMO is a performance measurement
of the process capability assessment.
The calculation shows that the DPU (Defects P Control Chart
Per Unit) value is 0.099 from the division between 0,3
the number of defective products and the total
0,2
sample. After the DPU value is known, you can
find the DPMO value by multiplying the DPU 0,1
value by one million and dividing it by the CTQ,
which is eleven. The results from DPMO during 0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
July 2019 amounted to 9097.48. The results of the
calculation of the DPMO value after being Cacat UCL LCL CL
converted into a six sigma value produce a sigma
value of 3.86. This value represents that after one Figure 2. P Control Chart
million products of 20 OE yarn are produced. It is
possible to obtain 9,098 defective or defective

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Table 2 Sigma Capability Level

Number of Number of Number of Potential

No DPM Sigma
Products Defects CTQ Causes Defects
1 430 43 11 9090.91 3.86
2 284 30 11 9603.07 3.84
3 376 49 11 11847.20 3.76
4 300 23 11 6969.70 3.96
5 288 32 11 10101.01 3.82
6 373 24 11 5849.38 4.02
7 288 24 11 7575.76 3.93
8 392 25 11 5797.77 4.02
9 360 27 11 6818.18 3.97
10 380 22 11 5263.16 4.06
11 288 56 11 17676.77 3.60
12 392 20 11 4638.22 4.10
13 376 29 11 7011.61 3.96
14 380 38 11 9090.91 3.86
15 352 15 11 3873.97 4.16
16 392 29 11 6725.42 3.97
17 388 58 11 13589.50 3.71
18 384 47 11 11126.89 3.79
19 368 32 11 7905.14 3.91
20 384 29 11 6865.53 3.96
21 304 29 11 8672.25 3.88
22 368 19 11 4693.68 4.10
23 376 35 11 8462.28 3.89
24 382 46 11 10947.17 3.79
25 320 52 11 14772.73 3.68
26 392 75 11 17393.32 3.61
27 318 44 11 12578.62 3.74
28 324 34 11 9539.84 3.84
29 364 39 11 9740.26 3.84
30 376 36 11 8704.06 3.88
Jumlah 10699 1061 11 9097.48 3.86

Table 3 Description of Formulas

Notation Formula
PDF = Number of Defects/Total Sample
DPM = DPU*1000000/Number of CTQ
Sigma Value = normsinv((1000000-DPMO)/1000000)+1.5

Analyze stage 20 OE yarn defect products is still in a controlled

The image p control chart can be interpreted stage. No point is uncontrolled other than the
as a cyclic pattern. This pattern can arise due to point exceeding the upper and lower control
the environment, for example, changes in levels (exceeding 3). However, there is still a need
temperature, electric voltage, shift operator. for quality control of the product.
But it can also be caused by other than the
environment, such as operator fatigue and tool Improvement Stage
wear. The p control chart shows that the process The next step is to develop improvement
capability can meet the expected tolerance limit steps using the 5W + LH method. At this stage, it
specifications, which means that the proportion of relates to ways that can be done to minimize or

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even prevent the product from defects. includes improvements to the PCB to synchronize
Improvements are obtained from solutions based the counter sensor and the diameter sensor. In
on the measurement results and analysis stages in contrast, from the mechanical side, it includes the
the previous stages. The most significant replacement of spare parts. What needs to be
contribution to the occurrence of defects in the considered is the mechanical repair of machines
yarn and being a priority for improvement steps is because many machines experience part wear.
the type of defect over doffing, underweight, and After all, spare parts are used continuously even
bad rolls. In the 5W + 1H table, what column though they have experienced wear. This repair
describes the type of defect, why column explains requires firmness on the company's part to
the cause of the defect, where the defect occurs, continue following the scheduling of machine
when the queue, when the defect occurs, who maintenance to minimize defective products. The
column about, who needs to repair, and how to machine maintenance schedule is replacing worn
take corrective action. The action plan to improve parts and cleaning the machine from cotton
Six sigma quality can be seen in Table 4. scraps because that is also one of the causes of
Based on the root causes determined defective products.
through 5W + 1H, one solution that deserves to Engine repair solutions are essential because
be discussed to reduce or eliminate the root of this is the root of the problem that causes over
the problem is engine repair, both from an doffing as the highest defect caused by wear of
electrical and mechanical side. The electrical side parts and contributes ± 80% of defects from all

Table 4. 5W+1H Over doffing

What Why Where When Who How

- The diameter sensor fails to detect - Repair PCB for
Autocor
causing the automatic cut process not to synchronizing counter
Over doffing Machine Juli Mechanic &
work. and diameter censor
(Weight +) 4 SE 8 2019 Electrician
- The magnet which measures length - Schedule for spare part
Corolab
doesn't function properly normal changing

Table 5. 5W+1H Less Weight

What Why Where When Who How
Stain material causing measuring head Autocoro
Weight Juli Improvement of choosing
automatically cut thread impact to increase Machine 4 SE Operator
(-) 2019 material quality
of thread connection. 8 corolab

Table 6. 5W+1H Poor Roll

What Why Where When Who How

- Attachment between the rotor

and twin disk does not fit. - Check component every scouring
Autocoro
- Uncenter Twin disk position. Maintenance and maintenance ensure every
Poor Machine 4 Juli
- Loose navel from the adapter. component in good condition.
Roll SE 8 2019
- The bearing tray is worn out. corolab
- Stain Rotor Operator - The operator always cleans waste
- The adapter is thread clogged. on the machine.

Table 7. 5W+1H Deflated Roll

What Why Where When Who How
Deflated - Broken Rubber drum Autocoro - Schedule
- Spring on package cradle malfunction Juli
and Thigh Machine 4 SE 8 Maintenance Spare art
causing cause Thigh Thread 2019
Roll corolab change

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defects that occur in one month. In addition to that as many as one million yarn products, it is
machine repair, another solution is to improve the possible to obtain a defect product of 9.098.
quality of the material. This repair is vital because The 20 OE yarn production process in July
good material will help the machine not cut the 2019 in the p control chart can be interpreted
yarn too often. This repair causes the defect to be as a cyclic pattern. This pattern can arise due
less heavy by cutting too many threads, making to the wear of parts. Based on Kaizen
the raw materials used inefficient because they implementation tools, proposals for quality
are wasted. Skills and accuracy also need to be control and improvement need tighter
improved in terms of human resources because supervision and control, especially regarding
getting maximum results depends on the human the wear of components used on autocross
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