Overcoming Quality Control Challenges in Car Exhaust Manufacturing

Indonesian Journal of Innovation Studies Pub Date : 2024-06-12 DOI:10.21070/ijins.v25i4.1188

Moch. Agung Setiono, A. S. Cahyana

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Abstract

PT. XYZ, a manufacturer of car exhaust components, faces significant defect-related challenges, impacting productivity and market competitiveness, particularly in Europe. Over six months, 3.18% of 184,708 produced components were defective. This study aims to determine the sigma level of quality control and identify root causes of defects using the Six Sigma DMAIC method and Root Cause Analysis (RCA). Observations and interviews revealed human error, machine issues, improper methods, substandard materials, and environmental factors as key contributors to defects. The sigma level was found to be 4, indicating suboptimal quality control. Recommendations for improvement include SOP development, operator training, standardized production methods, regular machine maintenance, and 5S organizational practices. Implementing these could reduce defects and improve productivity. Highlight: Defect Rate: 3.18% in 184,708 components. Sigma Level: Evaluated at level 4. Improvements: Implement SOPs, training, maintenance, 5S practices. Keyword: Quality Control, Six Sigma, Root Cause Analysis, Manufacturing, Car Exhaust Components

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克服汽车排气管制造中的质量控制挑战

PT.XYZ 是一家汽车排气部件制造商，面临着与缺陷有关的重大挑战，影响了生产率和市场竞争力，尤其是在欧洲。在六个月内，生产的 184 708 个部件中有 3.18% 存在缺陷。本研究旨在确定质量控制的西格玛水平，并利用六西格玛 DMAIC 方法和根源分析 (RCA) 找出缺陷的根本原因。通过观察和访谈发现，人为错误、机器问题、不当方法、不合格材料和环境因素是造成缺陷的主要原因。发现西格玛水平为 4，表明质量控制不理想。改进建议包括制定 SOP、操作员培训、标准化生产方法、定期机器维护和 5S 组织实践。实施这些措施可以减少缺陷，提高生产率。亮点：缺陷率：184 708 个部件中的 3.18%。西格玛水平：评估为 4 级。改进措施：实施 SOP、培训、维护和 5S 实践。关键词：质量控制质量控制、六西格玛、根源分析、制造、汽车排气部件

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Indonesian Journal of Innovation Studies

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