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1

Minimizing Product Defects Based on Labor Performance using Linear Regression and Six Sigma Approach

Nurprihatin Filscha, Ayu Yayang Nadistya, Rembulan Glisina Dwinoor, Andry Johanes Fernandes, Lestari Tika Endah

Management and Production Engineering Review

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2023

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Vol. 14, No. 2

88--98

EN

The objective of this research is to minimize product defects based on labor performance and prove the hypothesis on how labor performance affects the quality of a product through a scientific calculation using Overall Labor Effectiveness (OLE). The primary data is obtained by interviewing the supervisor and labor directly. For secondary data is obtained from the company, such as labor working time, machine scheduled downtime, total production, and defective products. The approach to extract the data is using OLE and the continued regression method. Furthermore, it proceeds to Six Sigma using the DMAIC approach since the results show a significant correlation. The result from Failure Mode and Effects Analysis (FMEA) shows four of six potential failures caused by product defects are coming from labor. To prevent failure mode, it is recommended to have the regular machine checked by labor, check the temperature of the machine, and provide Standard Operating Procedures.

2

Integration of Overall Equipment Effectiveness and Six Sigma Approach to Minimize Product Defect and Machine Downtime

Nurprihatin Filscha, Rembulan Glisina Dwinoor, Andry Johanes Fernandes, Lubis Maulidina, Widiwati Ivana Tita Bella, Vaezi Ali

Management and Production Engineering Review

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2023

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Vol. 14, No. 4

71--91

EN

This study was conducted in a company that produces palm oil-based products such as cooking oil and margarine. The study aimed to encounter defects in packaging pouches. This study integrated the overall equipment effectiveness (OEE) with the six sigma DMAIC method. The OEE was performed to measure the efficiency of the machine. Three factors were measured in OEE: availability, performance, and quality. These factors were calculated and compared to the OEE world-class value. Then, the Multiple Linear Regression was performed using SPSS to determine the correlation between measurement variables toward the OEE value. Lastly, the six sigma method was implemented through the DMAIC approach to find the solution and improve the packaging quality. Supposing the recommendations are implemented, the OEE is expected to increase from 82% to 85%, with availability ratio, performance ratio, and quality ratio at, 99%, 86%, and 99.8%, respectively.

3

Supply Chain Disruptions Mitigation Plan Using Six Sigma Method for Sustainable Technology Infrastructure

Andry Johanes Fernandes, Nurprihatin Filscha, Liliana Lydia

Management and Production Engineering Review

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2022

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Vol. 13, No. 4

88--97

EN

Supply Chain Management (SCM) is a very important part of the industrial world, especially in the manufacturing sector. The development of the business world affects the complexity of the supply chain due to the lack of logistics infrastructure, quality of materials and components, and much more. Supply chain disruption risk mapping needs to be done due to high uncertainty, which is overcome by implementing a decision support system. Based on the background of the problem, supply chain disruption mapping uses the help of the Six Sigma method, which consists of 5 stages: Define, Measure, Analyze, Improve, and Control (DMAIC). The measurement of disturbance also uses the Failure Mode and Effect Analysis (FMEA) approach to prioritize risk. Risks that have a high assessment and cause failure need to be prioritized for improvement. This study aims to map supply chain disruptions in the current manufacturing industry based on the barriers, resistances, and causes detected for making a decision support system prototype. By implementing a decision support system in the supply chain process, it is hoped that the manufacturing industry can minimize potential losses from existing risks.

4

The Application of Six Sigma for Process Control Analysis in the Malaysian Poultry Wastewater Treatment

Ishak Anuar Bin, Mohamad Effendi Bin, Arep Hambali Bin Arep

Journal of Ecological Engineering

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2022

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Vol. 23, nr 5

116--129

EN

In this paper, the researchers presented the process control analysis of a Poultry Wastewater (PWW) treatment plant that was designed to comply with the Environmental Quality (Industrial Effluent) Regulations, 2009. In this pilot case study, the researchers highlighted the fact that owing to the existing global environmental challenges, a Six Sigma approach needs to be used for developing a new technique that helps in optimising process capability and assesses the treatment reliability. This would allow the effective treatment of different pollutants like pH, BOD5, TSS, COD, O&G and NH3-N before their discharge into the environment. The researchers used several quality control process tools like the I-MR control charts, treatment process capability analysis and treatment reliability assessment in the study. After analysing the data, the researchers concluded that the plant could effectively treat NH3-N, as well as fairly decrease the pH, BOD5, and COD values, whereas it displayed low ability in treating TSS and O&G within the research period. The researchers noted that the process showed low reliability in the treatment of TSS and O&G, i.e., 88.6% and 29.8% respectively, led to the discharge of fine colloids in the effluent. This was attributed to problematic processes in the PWW treatment procedure, such as malfunction of the DAF unit process, ineffective physical-chemical treatment, and tertiary filtration breakdown. The researchers concluded that this PWW plant required additional control and design improvement so that it released a low concentration of toxic compounds in the effluent discharge, and complied with the standards. This research could be used as a reference for additional studies that aimed to improve the quality of the wastewater treatment processes.

5

Consistency of DMAIC phases implementation on Six Sigma method in manufacturingand service industry: a literature review

Trimarjoko Aris, Purba Humiras H., Nindiani Aina

Management and Production Engineering Review

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2020

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Vol. 11, No. 4

34--45

EN

High business competition demands business players to improve quality. The Six Sigma with DMAIC phases is a strategy that has proven effective in improving product and service quality. This study aims to find the consistency of DMAIC phases implementation and analyze the objective value in Six Sigma research. By using a number of trusted article sources during 2005 until 2019, this research finds that 72% research in manufacturing industry consistently implemented DMAIC roadmap especially in case study research type for problem-solving, while service industry pointed out the fewer number (60%). The causes of variations and defective products in the manufacturing industry are largely caused by a 4M 1E factor, while in service industry are caused by human behavior, and it’s system poorness. Both manufacturing & service industry emphasized standardization & monitoring to control the process which aimed at enhancing process capability and organization performance to increase customer satisfaction.

6

Wdrażanie zintegrowanego systemu zarządzania w przedsiębiorstwach górniczych

Bąk P., Nowak A.

Przegląd Górniczy

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2018

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T. 74, nr 9

27--34

PL

Zintegrowany system zarządzania jest połączeniem procesów, procedur i praktyk działania stosowanych w organizacji w celu wdrożenia jej polityki, które może być bardzo skuteczne w osiąganiu celów wynikających z polityki. Jego wdrożenie jest bardzo korzystnym rozwiązaniem dla przedsiębiorstwa, które stosuje kilka różnych systemów zarządzania. Najczęściej dotyczy to zarządzania jakością, środowiskiem, bezpieczeństwem pracy oraz bezpieczeństwem informacji, postrzeganych wcześniej oddzielnie. Przyjęcie zintegrowanego systemu zarządzania umożliwiło skuteczne równoczesne zarządzanie wieloma podsystemami, poprzez ustanowienie i realizację jednolitej polityki firmy. Celem artykułu jest przedstawienie wybranych działań wdrażania zintegrowanego sytemu zarządzania w przedsiębiorstwach górniczych. Praca prezentuje podstawowe zasady wdrażania sytemu oraz kolejne jego etapy. Pokazano również przegląd zarządzania, który stanowi raport na temat działania zintegrowanych systemów zarządzania.

EN

An integrated management system is a combination of processes, procedures and practices used in the organization to implement its policy, which can be very effective in achieving policy objectives. Its implementation is a very advantageous solution for a company that uses several different management systems. Most often, it concerns quality management, environment, work safety and information security, previously seen separately. The adoption of an integrated management system has enabled the effective simultaneous management of many subsystems, through the establishment and implementation of a single company policy. The aim of this paper is to present selected activities of implementing an integrated management system in mining enterprises. The work presents the basic principles of implementation of the system and its subsequent stages. An overview of management is also presented, which is a report on the operation of integrated management systems.

7

Impact of enterprise maturity on the implementation of Six Sigma concept

Kosieradzka A., Ciechańska O.

Management and Production Engineering Review

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2018

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Vol. 9, No. 3

59--70

EN

Six Sigma as the continuation of comprehensive quality management TQM is of interest to many enterprises. Unfortunately, not everybody successfully implements quality improvement projects using Six Sigma tools. This approach requires proper preparation in many areas of the company’s operation, including: organization of processes, establishing measures, employee engagement and creating conditions for continuous improvement. The goal of the article is to present on the case study the idea of using the organizational maturity model for production management to assess a readiness of organization to implement Six Sigma. The case study presents a company maturity level diagnosis and a successful project of quality and productivity improvement using the Six Sigma concept, confirming that the organization’s maturity model is the appropriate tool for assessing multi-faceted preparation for successful implementation of Six Sigma projects.

8

Analiza poziomu wdrożenia kompleksowego utrzymania ruchu (TPM) na przykładzie firmy z przemysłu elektrotechnicznego

Świtek S.

Zeszyty Naukowe Politechniki Poznańskiej. Organizacja i Zarządzanie

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2017

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Nr 73

273--287

PL

W pracy przedstawiono wyniki wdrożenia koncepcji Kompleksowego Utrzymania Ruchu (TPM) w jednym z zakładów produkcyjnych na terenie Polski, będącym filią międzynarodowej korporacji działającej w branży elektrotechnicznej. Celem badania było potwierdzenie korzyści uzyskiwanych z programu TPM, jednakże na poziomie całego zakładu. Było to zadanie złożone dla tego studium przypadku z uwagi na różnorodność i ilość wyposażenia produkcyjnego. Zebrane dane na przestrzeni ostatnich kilku lat poddano analizie, a jej wynik potwierdza nie tylko słuszność postawionej tezy o skuteczności koncepcji TPM do obniżenia poziomu awarii, ale również daje rekomendacje dla dalszego rozwoju koncepcji w tej firmie i wskazówki dla zarządu. W artykule podkreślono również efekt współdziałania koncepcji TPM z innymi programami ciągłego doskonalenia.

EN

This paper presents a substantial results of the concept of Total Productive Maintenance in one of production sites in Poland, which is a subsidiary of an international corporation operating in the electronic industry. The aim of the study was to confirm the common benefits derived from the TPM program, but at the level of the whole plant, which was a complex task for this case study because of the variety and quantity of production equipment utilized. The data collected over the last few years were analyzed, and the result confirms not only the validity of the bet thesis about the effectiveness of TPM to reduce the level of breakdowns but also gives recommendations for the further development of the improvement initiative in this company and guidance to the board. The article also highlights the effect of interaction between TPM and other programs of continuous improvement.

9

Charakterystyka modeli przywództwa stosowanych w organizacjach Lean i Six Sigma

Świtek S.

Organizacja i Zarządzanie : kwartalnik naukowy

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2016

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nr 4

139--155

PL

Artykuł przedstawia najczęściej stosowane modele przywództwa w organizacjach, w których wdrożono koncepcje lean i six sigma. Omówiony został wpływ aspektu kulturowego na efektywność stylu kierowania oraz różnice w podejściu do przywództwa w koncepcjach ciągłego doskonalenia.

EN

In the article presented the most used leadership models in organizations, where lean and six sigma improvement methodologies have been implemented. Influence of cultural aspect on managerial style effectiveness and differences in approaches to leadership style in continual improvement methodologies is discussed.

10

Methodology to identify the causes of the consequences of defects in building construction

Piasny J., Pasławski J.

Czasopismo Techniczne. Budownictwo

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2014

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R. 111, z. 1-B

183--193

EN

To rationally prevent defects, you must first have knowledge of the defects, their causes and the associated costs. A key objective of the research presented is to attempt to demonstrate the application of various methods used in production engineering, in the context of today’s economy requirements and transfer knowledge gained from previously completed projects, with the aim of increasing the quality multifamily housing. A study of faults and subcontractors was carried out for the period 2006/2013. Eight construction projects with a total usable area of approximately 117,000.0 square meters and 1,524 apartments were studied. This is one of the first studies, for this period, carried out based on multifamily building projects in Poland.

PL

Aby wykonać racjonalną profilaktykę wad, trzeba mieć wiedzę na temat usterek, ich przyczyn i związanych z tym kosztów. Kluczowym celem badań prezentowanych jest podjęcie próby wykazania zastosowania różnych metod stosowanych w inżynierii produkcji w kontekście współczesnych wymagań gospodarki oraz przekazanie wiedzy zebranej z zrealizowanych projektów powodującej wzrost jakości w budownictwie wielorodzinnym. Badanie występujących usterek oraz podwykonawców przeprowadzono za okres 2006/2013. Przebadano osiem projektów budowlanych o łącznej powierzchni użytkowej ok 117.000,0 m2 i 1524 mieszkań. Jest to jedno z pierwszych przeprowadzonych badań w tym okresie dla budynków wielorodzinnych w Polsce.