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Ridwan, Asep
Sultan Ageng Tirtayasa University
Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Economics, Econometrics & Finance Engineering Industrial & Manufacturing Engineering Mechanical Engineering Transportation

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Analysis of ceramic product quality: A Six Sigma approach Ridwan, Asep; Sonda, Atia; Zilardhi, Athariq
Journal Industrial Servicess Vol 10, No 1 (2024): April 2024
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.62870/jiss.v10i1.24505

Abstract

In the industrial world, the quality and productivity of products play a crucial role in the success of various production systems. The ceramic industry encounters challenges related to defective products due to various factors. When COVID-19 struck, one ceramic tile company temporarily laid off workers and suspended operations at several plants due to a decrease in orders. In January 2023, the company only opened three plants. It was found that many problems were encountered particularly with the production of SL-type ceramic tiles (25 cm × 25 cm). They were still striving to reduce these issues and ensure smooth production processes. The problems that frequently occur can be attributed to the production process, materials, machinery, or human factors. Consequently, research has been conducted to control defective products, thereby enhancing production quality using the Six Sigma DMAIC method. The DMAIC methodology is the cornerstone of Six Sigma problem-solving, involving sequential improvement steps. These steps in the DMAIC method include Define, Measure, Analyze, Improve, and Control. Based on the conducted calculations, an average DPMO (Defects per Million Opportunities) value of 8621.2 was obtained, with an average sigma value of 3.91. DPMO, which measures failure in the DMAIC method, indicates failures per million opportunities. Based on this, it suggests that production falls within the average category of the Indonesian industry and is deemed sufficiently satisfactory. This study also provides improvement steps that need to be taken to reduce defective products.
Supply chain performance analysis using discrete system simulation method: A case study in a furniture company Trenggonowati, Dyah Lintang; Ulfah, Maria; Ridwan, Asep; Bahauddin, Achmad; Ekawati, Ratna; Sonda, Atia; Umyati, Ani; Fachrur, Aditya Rahadian; Yadi, Yayan Harry
Journal Industrial Servicess Vol 9, No 1 (2023): April 2023
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/jiss.v9i1.19049

Abstract

As time progresses, the evolving industrial world demands that companies devise the best strategies to achieve their desired goals. A well-designed system is expected to increase the profitability of the company itself. CSD is an interior furniture and interior design studio located in the city of Cilegon, Banten. The challenge faced by CSD is the inability to meet order deadlines during periods of high demand. The objective of this study is to assess the level of machine utility within the existing process and provide recommendations to achieve an optimal process. The methodology employed includes system simulation and model development using Promodel software. Additionally, statistical tests, model validation, and ANOVA tests were conducted. Based on the results, it was determined that the level of machine utility at CSD is 17.48% for shaping planning, 30.08% for grinding, 14.88% for assembly, and 29.98% for finishing. The proposed solution, scenario or proposal 2, suggests combining the assembly and finishing workstations, resulting in increased machine utility.
Product quality control analysis using the six sigma method Ridwan, Asep; Sonda, Atia; Amelia, Amelia
Journal Industrial Servicess Vol 9, No 1 (2023): April 2023
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/jiss.v9i1.19044

Abstract

Technological improvements and developments have significantly altered consumers' perceptions of product quality. The production of high-quality products is only possible through a robust manufacturing process. However, during the production process, various issues may arise, leading to the production of defective products. As a result, manufacturing companies like XYZ are now required to conduct product quality control to minimize the number of defects. The objective of this study is to control product quality by reducing defects at XYZ. To achieve this, we have employed the Six Sigma method, which involves several stages, such as define, measure, analyze, improve, and control. Our research indicates that product A is prone to defects, with density being the most common type. We have calculated the DPMO (defects per million opportunities) to be 2580.66, while the sigma value is 4.297. The process capacity that produces problems at XYZ is at an average level for US industry. Additionally, we have used the 5W + 1H approach to propose improvements during the Improve stage. However, our recommendation for enhancing the production process to reduce defects is still a work in progress and needs to be executed, assessed, and monitored to reach world-class industry standards.
Penerapan metode six sigma dalam pengendalian kualitas di industri tekstil PT XYZ Trenggonowati, Dyah Lintang; Ridwan, Asep; Ulfah, Maria; Herlina, Lely; Bahauddin, Achmad; Ekawati, Ratna; Arina, Faula; Ferdinant, Putro Ferro; Sonda, Atia; Fachrur, Adhitya Rahadian
Journal of Systems Engineering and Management Vol 1, No 1 (2022)
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/joseam.v1i1.17587

Abstract

Perkembangan dunia industri sekarang mengakibatkan semakin banyaknya persaingan dalam dunia industri khususnya bidang tekstil. Dalam persaingan yang semakin ketat ini, perusahaan harus perusahaan harus mampu mempertahankan jumlah pelanggan dengan cara menjaga kualitas produk. PT. XYZ merupakan salah satu perusahaan industri penenunan label yang terletak di Tangerang Banten Indonesia, dengan produk yang paling banyak diproduksi adalah woven label. Banyaknya permintaan dari produk woven label ini diperlukan kualitas yang baik untuk memenuhi kriteria konsumennya. Oleh karena itu, diperlukan proses produksi yang juga sesuai dengan prosedur yang ditetapkan. Permasalahan yang terdapat pada PT. XYZ adalah banyaknya produk reject pada bagian produksi dan finishing. Hal ini ditunjukan pada data reject yang terjadi di bulan Desember 2021 sebanyak 1.285.876 dozen dan proses produksi yang belum terkendali secara statistic karena banyaknya jenis cacat (CTQ) sebesar 19 jenis. Banyaknya reject woven label ini mengakibatkan produksi tidak sesuai yang dijadwalkan, biaya operasional bertambah dan keuntunganpun bisa menurun. Oleh karena itu, PT. XYZ perlu melakukan perbaikan pengendalian kualitas yang salah satu caranya dengan metode Six Sigma. Tahapan pengendalian metode six sigma dilakukan dengan melakukan tahapan DMAI atau Define, Measure, Analyze, dan Improve. Berdasarkan hasil pengolahan data diperoleh nilai DPMO sebesar 2454,102 dan nilai sigma 4,318 yang berarti perusahaan merupakan rata-rata industri USA. Usulan yang peneliti berikan untuk PT. XYZ untuk mengurangi kecacatan yaitu dengan menetapkan settingan tension beam yang tepat disetiap produksi, membuat desain garis untuk pemotongan agar saat dipotong, garis tepi dapat lurus,  menyamakan persepsi atau membuat standar terkait reject PGM, operator mengontrol mesin setiap beberapa menit, dan mengganti benang yang sudah mau putus, agar mesin distop manual.
Quality control analysis in tofu production using Lean Six Sigma and Design of Experiments to reduce defects Ridwan, Asep; Trenggonowati, Dyah Lintang; Nur'aini, Nur'aini
Journal Industrial Servicess Vol 10, No 2 (2024): October 2024
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.62870/jiss.v10i2.29642

Abstract

This research focuses on the quality issues faced by a micro, small, and medium enterprise (MSME) in the food sector, specifically in tofu production. The production process still generates defective products, with a defect rate of 2% to 3% per day. Further observations identified several types of waste in the production process, including overproduction, defects, motion, waiting, transportation, and overprocessing, with defects being the most dominant. To address this issue, this study applies to the Lean Six Sigma method to control product quality. Through analysis using a questionnaire on the seven types of waste, five Critical to Quality (CTQ) factors were identified: dirty defects, splitting defects, hole defects, size defects, and color defects. The study also analyzes the production cycle time, revealing a lead time of 9 hours and 50 minutes, with a total value-added time of 7 hours and 49 minutes. The Defects Per Million Opportunities (DPMO) value is 5,605.31, and the sigma value is 4.0364, indicating that product quality is at an average industry level. An improvement plan was formulated using an experimental design. The proposed improvements were implemented by setting the soybean soaking time to 4 hours, the boiling time to 30 minutes, and the coloring time to 2 hours. After implementation, the percentage of defective tofu products decreased from 2.13% to 0.32%. These results demonstrate that applying the Lean Six Sigma method significantly enhances product quality and production efficiency for the MSME.
Co-Authors Achmad Bahauddin Aditya Rahadian Fachrur Amelia Amelia Arina, Faula Atia Sonda Ekawati, Ratna Fachrur, Adhitya Rahadian Ferdinant, Putro Ferro Herlina, Lely Nur'aini, Nur'aini Sonda, Atia Trenggonowati, Dyah Lintang Ulfah, Maria Umyati, Ani Yadi, Yayan Harry Zilardhi, Athariq