Implementation of Lean Manufacturing for Improvement of Gas Pipe Product Quality with Six Sigma Approach and Value Stream Mapping in Oil and Gas

Abstract

A company in the oil and gas manufacturing industry produces gas pipe products using the Polyethylene model. During the period of January to June 2020, the company experienced a defect rate of 2% in the total production. This research utilized a descriptive method to analyze the production process in order to identify and eliminate the rejected products. The objective of this study was to achieve a decrease in defects below 2%. By applying the Six Sigma (DMAIC) method and conducting calculations and analysis, an improvement proposal was developed to address the defects found during the Radiography Test. The proposed solution involves providing specialized training for workers, implementing clear procedures and methods for work, and conducting training sessions to enhance operator skills and understanding of Standard Operating Procedures (SOPs). As a result of the proposed improvements, a comparison of cycle times was conducted. Prior to the implementation of the improvements, the cycle time was 390 minutes. However, after the implementation, the cycle time reduced significantly to approximately 245 minutes. Overall, the proposed improvements aim to reduce the defect rate below 2% and optimize the production process for gas pipe products with the Polyethylene model in the oil and gas manufacturing company.