<![CDATA[This research aims to reduce quality defects in cylinder block components supplied to PT. Automotive Manufacturing Indonesia (PT. AMI). In 2024, the company experienced a 4.42% defect rate and a first pass yield (FPY) of 95.01% in its cylinder block machining line, leading to over IDR 17 billion in losses. Defects such as leakage and porosity were only detected after further machining, indicating weaknesses in the supplier’s casting and inspection processes. The study applies the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology to identify root causes, reduce variation, and improve product quality. The objective is to lower the defect rate to below 2%, increase FPY, and establish a sustainable quality control approach. The research stages include identifying critical-to-quality (CTQ) factors, analyzing defect trends using statistical tools, evaluating root causes through visual inspection and cross-sectional cuts, and testing improvement actions in trial runs. Results show that improvements such as cooling pin addition and die temperature control led to a significant defect reduction, including a 0% defect rate in ventilation hole leakage after implementation. A monitoring and control plan was established to maintain long-term quality performance. This study demonstrates that Six Sigma can be effectively extended beyond internal processes to supplier-side quality improvement. The findings provide a practical model for other manufacturing firms facing similar challenges, highlighting the importance of structured collaboration, data analysis, and preventive quality control in managing outsourced components.]]>
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