<![CDATA[Purpose – This study aims to reduce product defects and improve quality performance in tofu stick production at UD. Maju Jaya Sejahtera through the implementation of the Six Sigma approach. The research seeks to identify dominant defect types, analyze root causes, and formulate quality improvement strategies to enhance competitiveness and operational sustainability in food SMEs. Design/Methodology/Approach – This study employs a descriptive research approach by analyzing tofu stick production data over a three-month period from September to November 2024. The research applies the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework supported by SIPOC diagrams, CTQ Trees, Control Charts, Pareto diagrams, Fishbone diagrams, and DPMO and sigma level calculations. Failure Mode and Effect Analysis (FMEA) is used to prioritize improvement actions based on identified failure risks. Findings – The findings indicate that the current production process operates at a 3.21 sigma level with a DPMO value of 43,367, demonstrating substantial opportunities for quality improvement. Pareto analysis identifies crumbled tofu sticks (66.35%) and burnt tofu sticks (22.14%) as the dominant defects. Root cause analysis reveals that these defects are primarily caused by improper storage and frying methods, insufficient worker understanding of procedures, and limited precision during production activities. The proposed improvements emphasize process standardization, worker training, and enhanced quality monitoring. Originality/Value – This study contributes to quality management research by integrating the Six Sigma DMAIC framework with multiple quality analysis tools to optimize production processes in traditional, labor-intensive food SMEs. The research provides a practical and measurable quality improvement model that can help small food manufacturers reduce defects, improve efficiency, and maintain long-term operational sustainability.]]>
