Reducing Wall Shelf Product Defects Using the DMAIC Method in Furniture Industry Companies

Abstract

The object of research is a place of business that produces household needs and wood-based industries. One of the products it produces is a minimalist wall shelf. In the period January – December 2021 minimalist wall shelf products are the products with the most defects. Manufacturing companies in this study have a product defect tolerance limit of 5% of the total production, but minimalist wall shelf products have a defect of 5.64%. This study aims to determine the types of defects that occur in wall shelf products, identify the causes of defects minimalist wall shelves and provide suggestions for improvements to reduce the number of future defects. In this research the method used is DMAIC. In the minimalist wall shelf production process, 4 types of defects were found. Based on the Pareto diagram, it was determined that the type of lacquer defect was not suitable to be the most dominant type of defect, namely 80.1%, it was also found that the DPMO value and sigma value on minimalist wall shelves were 14,100 and 3.69. Based on the analysis of the fishbone diagram method and Failure Mode and Effect Analysis (FMEA), it is known that the main root cause of product defects is a dirty, dusty and windy environment with an RPN (Risk Priority Number) value of 448. Analysis was carried out using the 5W + 1H approach to find improvements to overcome the problems that occur, obtained suggestions for improvements for the company, namely making work area picket schedules, making closed work areas, daily and monthly check sheet forms for maintenance of work tools, making varnish process work instructions, making training schedules for operators and submitting additional goods forms.