<![CDATA[Purpose – This study is motivated by the recurring occurrence of product defects in the reverse engineering process of power plant components at PT PLN Pusharlis, both during the production stage and after the components are installed and operated (after-sales). Such defects have the potential to affect component reliability and the operational performance of national power plants. Therefore, this research aims to analyze the level of product defects and the process capability of reverse engineering components at PT PLN Pusharlis, as well as to formulate systematic and data-driven quality improvement efforts. Methodology/approach – The research employs a mixed-methods approach by integrating quantitative and qualitative methods. Quantitative data are obtained from Non-Conformance Report (NCR) records and after-sales defect data for the period 2021–2024, which are analyzed to calculate CTQ, DPMO, and sigma levels. Qualitative data are collected through process mapping using SIPOC, cause-and-effect analysis with Fishbone 6M, and semi-structured interviews with relevant personnel involved in the production process. All stages of analysis are structured according to the DMAIC framework and are conducted up to the formulation of quality improvement recommendations Findings – It was found out that the application of the Six Sigma method with the DMAIC approach has proven effective in identifying, analyzing, and formulating solutions to product defect problems at PT PLN Pusharlis. Novelty - conducting a systematic evaluation of the reverse-engineering production process at PT PLN PUSHARLIS, with a specific focus on identifying dominant defect types, analyzing their root causes, and assessing the capability and stability of the production process]]>
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