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All Journal Indonesian Journal of Innovation Studies Academia Open
Dira Ernawati
Program Studi Teknik Industri, Universitas Pembangunan Nasional “Veteran” Jawa Timur
Computer Science & IT Education Engineering Law, Crime, Criminology & Criminal Justice Medicine & Pharmacology Public Health

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Lean Six Sigma Evaluation of Melamine Paint Delivery Quality Performance: Evaluasi Lean Six Sigma terhadap Kinerja Kualitas Pengiriman Cat Melamine Nurul Amalliyah; Dira Ernawati
Indonesian Journal of Innovation Studies Vol. 27 No. 3 (2026): July
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/ijins.v27i3.2008

Abstract

General Background Supply chain quality control is essential for ensuring that distributed products reach customers on time and in acceptable condition. Specific Background Melamine paint delivery involves several packaging types, including bottles, jericans, gallons, and pails, yet shipment defects still occur in the form of leaking gallons, burst gallons, dented pails, and broken bottles. Knowledge Gap Delivery quality studies still require integrated defect measurement and improvement prioritization that combines Lean Six Sigma, Root Cause Analysis, and Analytical Hierarchy Process in finishing material distribution. Aims This study evaluates the sigma level of melamine paint delivery defects and determines prioritized improvement actions to reduce shipment defects. Results Using Lean Six Sigma with the DMAIC approach, the study identified four Critical to Quality categories: leaking gallons, burst gallons, dented pails, and broken bottles. Pareto analysis showed that broken bottles were the dominant defect, with 463 cases or 66% of total defects, followed by dented pails at 15%, burst gallons at 13%, and leaking gallons at 6%. The average DPMO was 20,848, with a sigma level of 3.54. AHP weighting placed broken bottles as the highest-priority CTQ with a weight of 0.62. Novelty This study integrates Lean Six Sigma, RCA, and AHP to measure delivery defects and prioritize corrective actions. Implications Adding plywood bases to truck beds, stacking bottles by size, and arranging paint by delivery sequence can support better shipment quality control. Highlights: One packaging failure type accounted for 66% of total cases. Average DPMO reached 20,848 with a sigma level of 3.54. Top corrective actions focused on truck base protection and loading sequence. Keywords: Analytical Hierarchy Process, Defect, Lean Six Sigma, Melamine Paint, Root Cause Analysis
Waste Identification and Improvement in Raw Material Procurement Processes: Identifikasi dan Perbaikan Pemborosan dalam Proses Pengadaan Bahan Baku Ari Vera Hardiyanti; Dira Ernawati; Nur Rahmawati
Indonesian Journal of Innovation Studies Vol. 27 No. 3 (2026): July
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/ijins.v27i3.2009

Abstract

General Background: Efficient raw material procurement is essential for maintaining manufacturing flow, operational stability, and supply chain performance. Specific Background: PT XYZ, a steel plate and pipe fabrication company, faced procurement inefficiencies caused by non-value-added activities, delayed supplier delivery, limited storage capacity, repeated inspection, material returns, and suboptimal warehouse arrangement. Knowledge Gap: Previous studies have widely applied Value Stream Mapping to production processes, yet limited attention has been given to raw material procurement in steel fabrication, particularly through integrated waste mapping and risk prioritization. Aims: This study aimed to identify procurement waste and formulate targeted process recommendations using Value Stream Mapping, Failure Mode and Effect Analysis, and the 5W+1H framework. Results: The current condition showed a total lead time of 482 minutes, dominated by non-value-added activities. Waiting, defect, and overprocessing were the most critical waste categories, with Risk Priority Number values of 336, 315, and 252, respectively. Future Value Stream Mapping reduced total lead time to 318 minutes, yielding a 164-minute reduction. Novelty: The study integrates VSM and FMEA to connect process visualization with risk-based priority setting in raw material procurement. Implications: The findings provide a structured basis for supplier coordination, material quality standardization, inspection simplification, administrative streamlining, and procurement efficiency in steel fabrication operations. Highlights: Initial duration decreased from 482 to 318 after redesign. Waiting, defects, and overprocessing carried the highest risk priorities. The 5W+1H framework directed supplier, quality, inspection, and administration actions. Keywords: Failure Mode and Effect Analysis (FMEA), Raw Material Procurement, Value Stream Mapping (VSM)
Optimizing Animal Feed Raw Material Inventory Control Using the Min-Max Stock Method as an Effort to Minimize Inventory Costs : Optimalisasi Pengendalian Persediaan Bahan Baku Pakan Ternak Menggunakan Metode Min-Max Stock Sebagai Upaya Meminimalkan Biaya Persediaan Mahendra Putra Prasetiawan; Dira Ernawati
Academia Open Vol. 11 No. 2 (2026): December
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/acopen.11.2026.14203

Abstract

General Background: Reliable raw material control is essential for operational continuity because excessive and insufficient supplies can disrupt production and increase expenditure. Specific Background: Fluctuating demand at an animal feed manufacturer created recurring overstock and stockout conditions for Pollard, Soya Bean Meal, Full Fat Soya, and Crude Palm Oil. Knowledge Gap: The company’s existing policy did not establish coordinated safety quantities, minimum and maximum levels, reorder points, and ordering frequencies based on historical usage. Aims: This study evaluates the Min Max Stock method for controlling four principal broiler feed materials and lowering total expenditure. Historical purchasing and consumption records from May 2025 to April 2026 were collected through observation and documentation. Current company calculations were compared with Min Max Stock calculations, while Weighted Moving Average and Single Exponential Smoothing supported demand forecasting. Results: The proposed approach generated savings of Rp23,850,000 for Pollard, Rp33,125,000 for Soya Bean Meal, Rp15,900,000 for Full Fat Soya, and Rp43,800,000 for Crude Palm Oil, equivalent to reductions of 48%, 45%, 36%, and 49%, respectively. Total savings reached Rp116,675,000, with annual ordering frequencies set at 18, 26, 20, and 23 times. Novelty: The study combines material-level control thresholds, order quantities, forecasting, and expenditure comparison within one operational framework for broiler feed production. Implications: The company should adopt the proposed policy and train relevant staff to maintain material availability while reducing overstock, stockout, and unnecessary expenditure. Highlights: Pollard generated an annual expenditure reduction of Rp23.85 million. SBM and FFS lowered annual spending by Rp33.125 million and Rp15.9 million. CPO achieved the greatest proportional decrease, with 23 planned orders annually. Keywords : Cost, Inventory, Raw Materials, Min-Max Stock
Co-Authors Ari Vera Hardiyanti Mahendra Putra Prasetiawan Nur Rahmawati Nurul Amalliyah