<![CDATA[General Background: Inconsistency in product quality due to process variation remains a challenge in many companies, impacting production efficiency and customer satisfaction. Specific Background: Similar problems often occur in the packaging industry in Indonesia. with product defect rates exceeding the 4% limit. Knowledge Gap: Previous study has focused mostly on using Six Sigma to improve product quality, but the integration of FTA and cost analysis has been limited. Aims: This study was conducted to analyse defect causing factors, analyse the cost of defective products, and evaluate the effectiveness of improved solutions in improving product quality. Result: The main findings show five main defect types i.e. hole in the sack defect, skewed stitching defect, melted sack defect, skipped stitching defect, and fuzzy sack defect, primarily caused by operator inattention, incorrect machine settings, and equipment malfunctions. After implementing, the defect rate decreased by 1.33% (9,894 units), and the sigma level increased from 3.98 to 4.11. This improvement generated cost savings of IDR 12,408,451. Novelty: Integration of Six Sigma, FTA, and cost analysis not only provides recommendations for improvement but also offers an analysis of the financial impact on the company. Implication: This study provides strategies for improving productivity and business sustainability through the reduction waste, cost savings, and the strengthening of practical field practices. Highlights: Five defect types represented approximately 80% of total defects. Pilot testing reduced defects by 9,894 units, from 4.52% to 3.19%. The proposed solution produced IDR 12,408,451 in cost savings. Keywords: Six Sigma, Defect, Reduce Waste, Cost Analysis, Woven Bag]]>
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