<![CDATA[Milk chocolate bar production requires consistent control of product appearance, weight, surface quality, and food safety. This study aimed to apply the Six Sigma Define, Measure, Analyze, Improve, and Control approach to reduce finished goods defects in milk chocolate bar production at PT. XYZ, West Sumatra, Indonesia. A mixed-methods design was used by combining production data, direct observation, measurement, structured interviews, and focus group discussion with production and quality control personnel. Defect data were analyzed using defect classification, Pareto analysis, defects per million opportunities calculation, sigma level measurement, fishbone analysis, and control planning. The results showed that finished goods defects reached 5.00%, exceeding the company tolerance limit of 3.00%. During eight months of observation, finished goods defects ranged from 3.90% to 6.00%, with total production of 4,135 kg and total defects of 204 kg. Non-standard shape was the dominant defect, contributing 62.96%, followed by blooming defects at 25.92%, insufficient weight at 7.41%, and physical hazards at 3.70%. Root causes were associated with operator skills, raw material particle size, foreign material inspection, demolding procedures, and unstable conching temperature. After gradual improvement, defects decreased to 20 kg from 520 kg production, defects per million opportunities decreased from 12,333 to 9,615, and sigma level increased from 3.7 to 3.9. The study demonstrates that Six Sigma-DMAIC can improve chocolate manufacturing quality, strengthen process control, and support food safety management in local food company.]]>
