Implementation of Six Sigma Methods with Failure Mode and Effect Analysis (FMEA) as a Tool for Quality Improvement of Newspaper Products (Case Study: PT. ABC Manufacturing – Sidoarjo, East Java – Indonesia)

Abstract

PT. ABC is a subsidiary of the JawaPos Group, founded in 1996, and is one of the companies in East Java engaged in printing and packaging. The products produced include magazines, books and newspapers. Of all the company's products, one of the most significant defects is found in newspaper products, which is 4% of the average newspaper production of 806.598 copies and produces a moderate defect of 22,743 copies in 2019. The research was conducted to analyze the sigma value and determine the factors of product defects and the impact of the defects to provide suggestions for product quality improvement. In this research, the method applied is the Six Sigma method and Failure Mode and Effect Analysis (FMEA), by implementing and carrying out the stages in the Six Sigma method, namely DMAIC (Define, Measure, Analyze, and Control). From this research, the results obtained are that the company has several newspaper product defects of 181,943 copies consisting of several types of product defects, including damp paper, blurred colours, shaded printing, asymmetrical printing, and running printing. The company is currently at the 4.04 sigma level, so corrective actions need to be taken to achieve six sigma levels. By applying the Failure Mode and Effects Analysis (FMEA) method, it can be seen that the most significant and most frequent product defect is the blurred colour defect. Therefore the recommended alternative solution for repairs is to check the ink and replace the ink with standard ink or have a lower density, perform regular and systematic machine checks, and provide further guidance on newspaper printing production standards to all operators involved.