<![CDATA[The high number of inner wrap defects in the packaging process affects product quality and production efficiency at PT Mayora Indah Tbk. The most dominant defect is the double inner wrap, which occurs when two or more products enter the subsequent packaging process simultaneously, resulting in products that do not meet quality standards. This study aims to identify the main causes of inner wrap defects, evaluate process capability using Six Sigma, analyze the root causes of defects, and propose a Poka-Yoke-based improvement. This research employed the Six Sigma method with the DMAIC (Define, Measure, Analyze, Improve, Control) approach. The Measure phase included data collection, Pareto analysis, and the calculation of Defects Per Million Opportunities (DPMO) and Sigma Level. The Analyze phase used the Fishbone Diagram and 5 Why Root Cause Analysis to determine the root causes of defects. The Improve phase proposed a Reject Trap, guide separator, modified screen diameter, and a hopper level sensor as Poka-Yoke devices. The Control phase consisted of implementing standard operating procedures, preventive maintenance, and periodic monitoring of process capability. The results showed that before improvement, total production reached 6,552,000 kg, with 72,450 kg of inner wrap defects (1.11%), a DPMO of 11,058, and a Sigma Level of 3.79σ. After implementing the proposed improvements, defects decreased to 18,860 kg (0.29%), representing a 73.96% reduction, while the DPMO decreased to 2,878 and the Sigma Level increased to 4.24σ. These findings demonstrate that integrating Six Sigma with the DMAIC approach and Poka-Yoke effectively reduces inner wrap defects, improves process capability, and supports a more preventive quality control system.]]>
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