Control of Production Process to Minimize Potential Failures Using Lean Six Sigma and Multi Attribute Failure Mode Analysis Approaches
Maria Ulfah1, Dyah Lintang Trenggonowati2, Ratna Ekawati3, Sherin Ramadhania4
Sultan Ageng Tirtayasa University
Abstract
Lean six sigma used to identify and eliminate non-valued waste along with continuous improvement of 6 sigma performance targets. Multi Attribute Failure Mode Analysis (MAFMA) is a method used to overcome the weaknesses in FMEA by considering the economic aspect. PT X is the largest steel industry in Indonesia. During the production process, still have large quantities of waste defect. The purpose of this research is to determine the waste that occurs in the production process, determine the characteristics of deformity or CTQ, determine the sigma value, determine the factors that caused the failure of the production process, and determine the proposed improvement to minimize the failure of the production process. The most dominant types of defects are serrated edge, wavy edge, poor cleanliness, pick up, edge crack, ripple edge, and bad weld. The sigma value of coldrolled coil product is 4,131 which is included into the industry average of USA (± 4σ). Factors that caused cold rolled coil production process failed based on criteria severity, occurrence, detection, and expected costs by Fuzzy Analytical Hierarchy Process (F-AHP) is material imported from outside with a total weight of 0,087. Proposed improvements done to minimize failure in cold rolled coil production processes are doing trial for products from HSM factory to test or know the slab specifications related to the chemical constituents of steelmaking and adjusting the format (such as thickness, length, width) and steel specifications to corresponding.
Keywords: Defect, failure, production process, waste
Topic: Industrial Engineering