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Implementing six sigma and Kaizen for quality improvement: A case of bottled water company in Makassar
Amar K.
Aip Conference Proceedings
Abstract
This study aims to identify and analyze the defects in a bottled water company in Makassar, Indonesia by implementing Six Sigma and propose the improvement using Kaizen. The secondary data obtained from the company showed that in its company production process found many defective products. Based on the Pareto Diagram, the dominant types of defects were dented cup (39.84%), tilted lids (17.15%), and lack of volume (12.85%). As plotted in a control chart, the process showed that not all data were within the control limits. At the same time, the average process capability level ( ) in one month was 4.83, similar to 483.16 dpmo. In analyze stage using the DMAIC methodology, the fishbone chart was identified the potential causes of the defects which come from man, machine and, material. The Kaizen 5W1H was used to propose some improvement recommendations to overcome the company’s defect problem. For instance, to minimize the dented cups, the authors suggested increasing workers’ understanding of the importance of being careful in moving raw materials and paying attention in handling lid waste. Some recommendations were also made regarding raw materials, i.e. do incoming material inspection using sampling. Workers should also select the cups before the whole cups in a slope are dropped into the bucket during the production process. While, to minimize the tilted lid defects, some recommendation was made; one of them is increasing the workers’ understanding of the importance of checking the lid position on the roll lid and bucket. Recommendations to minimize the lack of volume were also made; for example, the company should increase the understanding of workers on the importance of checking the volume of water in the water reservoir and filled cups to prevent defects.