Plastic Injection Quality Controlling Using the Lean Six Sigma and FMEA Method

PT. Yogya Presisi Teknikatama Industri (PT. YPTI) is a mold, precision part, and plastic injection maker company. One of the obstacles faced by the company is the high level of nonconformity on its production results. The waste on production process can be identified and classified into four types, i.e.: a). during the process of injection molding machines, b). finishing and cutting processes, c). quality control process and d). the packaging process. The objectives of this research are minimizing the defective goods and reducing the waste using Lean Six Sigma and FMEA approaches, especially for Bush product. From the analysis result, defective types on Bush product can be classified into bubble, speckle, short shoot, sunken, sink mark, over-cut, flashing, and discolor. Based on the attributes data on Bush product, the DPMO score is 988.42 or the sigma level is 4.6, While the DPMO score on the variable data on each dimension i.e.: a). Slit width on the bottom side has DPMO score of 30119 (sigma level 3.37), b). Diameter of the circle on the top side has DPMO score of 392294 (sigma level 1.77), c). Product thickness on the top side has DPMO score of 70474 (sigma level 2.97), d). Product height has DPMO score of 82107 (sigma level 2.89), product thickness on the bottom side has DPMO score of 24448 (sigma level 3.47), and f). Diameter of the circle on the bottom side has DPMO score of 24448 (sigma level 3.47). The highest RPN score on the dominant types of product defects which needs improvement are the defective goods of bubble type has RPN score of 729, flashing and the molten material out on the heating channel has RPN score of 384, over cutting has RPN score of 324 and sink mark has RPN score of 270. The recommendations for improvement that can be given from this research are making checklist for maintenance and production monitoring, enhancing work supervision and inspection, as well as improving the environment and work stations.