Email this article 
Quality Control of Garment Product Using DMAIC Six Sigma
Abstract
Quality control is intended to ensure that the products are in accordance with the predefined standards. PT. XYZ is a garment company that manufactures products with global target market. Hence, product quality assurance becomes an important issue for PT. XYZ. This research focuses on the Just Brand-MCJA216142 jacket product at the sewing work station on line-4 of PT. XYZ. Preliminary observations show that the number of reworked-products was experiencing an increasing trend. This study aims to determine whether the company has carried out quality control properly. Specifically, the research objectives are to identify the type and level of product defects, identify the factors causing product defects, and provide proper improvement suggestions to reduce the occurrence of product defects. This study applied DMAIC (Define–Measure–Analyze–Improve–Control) Six Sigma concept. The results showed that the quality of the Just Brand-MCJA216142 jacket product has exceeded the Indonesian industry average and is classified as the USA industry average. However, quality improvement is still needed since the products are targeted for the export market. Based on Pareto diagram at the Analyze stage, it was found that the most dominant defects occurred in the Just Brand-MCJA216142 jacket production process were broken threads and puckering. The frequency of occurrence for these two types of defect reaches 23% of the total 16 types of defects. The defects were caused by human, machine, material, method, and environmental factors. Recommendations for improvement at the Improve stage are based on root cause analysis of each causative factor that is identified using a fishbone diagram. This research results strengthen the previous related researches regarding the effectivity of DMAIC Six Sigma for analyzing quality control of products.
Keywords
Full Text:
PDFReferences
D. A. Garvin, “Product quality: An important strategic weapon,” Bus Horiz, vol. 27, no. 3, pp. 40–43, May 1984, doi: 10.1016/0007-6813(84)90024-7.
A. S. Putri and F. Primananda, “Quality Control on Minimizing Defect Product on 20 OE Yarn,” Jurnal Ilmiah Teknik Industri, vol. 20, no. 1, pp. 81–88, Jul. 2021, doi: 10.23917/JITI.V20I1.12443.
M. Stuart, E. Mullins, and E. Drew, “Statistical quality control and improvement,” Eur J Oper Res, vol. 88, no. 2, pp. 203–214, Jan. 1996, doi: 10.1016/0377-2217(95)00069-0.
A. V. Feigenbaum, Total Quality Control. New York: Graw Hill Book Inc, 1991.
A. Mitra, Fundamentals of quality control and improvement. John Wiley & Sons, 2016.
D. C. Montgomery, Introduction to statistical quality control. John Wiley & Sons, 2019.
X. Tang, M. Wang, and S. Wang, “A systematic methodology for quality control in the product development process,” Int J Prod Res, vol. 45, no. 7, pp. 1561–1576, Apr. 2007, doi: 10.1080/00207540600942367.
D. W. Ariani, Pengendalian Kualitas Statistik. Yogyakarta: Penerbit Andi, 2004.
M. A. Farooq, R. Kirchain, H. Novoa, and A. Araujo, “Cost of quality: Evaluating cost-quality trade-offs for inspection strategies of manufacturing processes,” Int J Prod Econ, vol. 188, pp. 156–166, Jun. 2017, doi: 10.1016/J.IJPE.2017.03.019.
C. F. Berardinelli, “To DMAIC or Not to DMAIC?,” Qual Prog, vol. 45, no. 11, p. 72, 2012, Accessed: Nov. 25, 2023. [Online]. Available: https://www.proquest.com/docview/1153823468
B. R. Krishnan and K. A. Prasath, “Six Sigma concept and DMAIC implementation,” International Journal of Business, Management & Research (IJBMR, vol. 3, no. 2, pp. 111–114, 2013, Accessed: Nov. 25, 2023. [Online]. Available: https://www.researchgate.net/publication/324029060_Six_Sigma_Concept_and_DMAIC_Implementation
R. G. Schroeder, K. Linderman, C. Liedtke, and A. S. Choo, “Six Sigma: Definition and underlying theory,” Journal of Operations Management, vol. 26, no. 4, pp. 536–554, Jul. 2008, doi: 10.1016/J.JOM.2007.06.007.
M. Patel and D. A. Desai, “Critical review and analysis of measuring the success of Six Sigma implementation in manufacturing sector,” International Journal of Quality and Reliability Management, vol. 35, no. 8, pp. 1519–1545, Sep. 2018, doi: 10.1108/IJQRM-04-2017-0081/FULL/PDF.
K. Gupta and G. Kumar, “Six sigma application in warehouse for damaged bags: A case study,” Proceedings - 2014 3rd International Conference on Reliability, Infocom Technologies and Optimization: Trends and Future Directions, ICRITO 2014, Jan. 2015, doi: 10.1109/ICRITO.2014.7014736.
B. Klefsjö, H. Wiklund, and R. L. Edgeman, “Six sigma seen as a methodology for total quality management,” Measuring Business Excellence, vol. 5, no. 1, pp. 31–35, Mar. 2001, doi: 10.1108/13683040110385809/FULL/PDF.
E. V. Gijo, S. Bhat, and N. A. Jnanesh, “Application of six sigma methodology in a small-scale foundry industry,” International Journal of Lean Six Sigma, vol. 5, no. 2, pp. 193–211, Jan. 2014, doi: 10.1108/IJLSS-09-2013-0052/FULL/PDF.
V. Gaspersz, Lean Six Sigma. Jakarta: Gramedia Pustaka Utama, 2007.
A. Rahman, S. U. C. Shaju, S. K. Sarkar, M. Z. Hashem, S. M. K. Hasan, and U. Islam, “Application of Six Sigma using Define Measure Analyze Improve Control (DMAIC) methodology in Garment Sector,” Independent Journal of Management & Production, vol. 9, no. 3, pp. 810–826, Sep. 2018, doi: 10.14807/ijmp.v9i3.732.
A. R. Heryadi and W. Sutopo, “Review Pemanfaatan Metodologi DMAIC Analysis di Industri Garmen,” in Prosiding Seminar dan Konferensi Nasional IDEC, Surakarta, 2018.
S. O. Parasayu and N. Susanto, “Analisis Six Sigma Untuk Peningkatan Kualitas Produk Line 28 Departemen Sewing Di PT. Apparel One Indonesia,” Industrial Engineering Online Journal, vol. 5, no. 4, pp. 343–354, 2016, doi: 10.2/JQUERY.MIN.JS.
P. Jirasukprasert, J. A. Garza-Reyes, V. Kumar, and M. K. Lim, “A six sigma and dmaic application for the reduction of defects in a rubber gloves manufacturing process,” International Journal of Lean Six Sigma, vol. 5, no. 1, pp. 2–22, Jan. 2015, doi: 10.1108/IJLSS-03-2013-0020/FULL/PDF.
A. A. Putri, M. Y. Lubis, and A. A. Yanuar, “Perancangan Usulan Perbaikan Proses Persiapan Aksesoris, Sewing, Dan Finishing, Pada Produksi Celana Jeans Di Pt. Xyz Dengan Metode Six Sigma,” in e-Proceedings of Engineering, 2019.
D. M. Zaman and N. H. Zerin, “Applying DMAIC Methodology to Reduce Defects of Sewing Section in RMG: A Case Study,” American Journal of Industrial and Business Management, vol. 07, no. 12, pp. 1320–1329, Dec. 2017, doi: 10.4236/AJIBM.2017.712093.
R. R. Deri, I. S. Nugroho, D. Nahwan, R. Ratik, and T. Malik, “Analysis of Quality Management System in the Textile Industry with the 5R/ 5S Method and Fish Bone Diagram,” Prosiding ICoISSE, vol. 1, no. 1, pp. 859–871, Dec. 2020, Accessed: Nov. 25, 2023. [Online]. Available: http://conference.loupiasconference.org/index.php/ICoISSE/article/view/118
B. A. D. Putri, Qurtubi, and D. Handayani, “Analysis of product quality control using six sigma method,” IOP Conf Ser Mater Sci Eng, vol. 697, no. 1, p. 012005, Dec. 2019, doi: 10.1088/1757-899X/697/1/012005.
A. Abidin and S. Sherly, “Pengukuran Keterkendalian Kualitas Produk Celana Jeans EDWIN VEGAS 01 dengan Metode Six Sigma di PT. Sapta Kharisma Cemerlang,” Akselerator : Jurnal Sains Terapan dan Teknologi, vol. 1, no. 2, pp. 45–52, Oct. 2020, Accessed: Nov. 25, 2023. [Online]. Available: https://jurnal.ubd.ac.id/index.php/aksel/article/view/450
F. P. Dharma, Z. F. Ikatrinasari, H. H. Purba, and W. Ayu, “Reducing non conformance quality of yarn using pareto principles and fishbone diagram in textile industry,” IOP Conf Ser Mater Sci Eng, vol. 508, no. 1, p. 012092, Apr. 2019, doi: 10.1088/1757-899X/508/1/012092.
J. Hossen, N. Ahmad, and S. M. Ali, “An application of Pareto analysis and cause-and-effect diagram (CED) to examine stoppage losses: a textile case from Bangladesh,” The Journal of The Textile Institute, vol. 108, no. 11, pp. 2013–2020, Nov. 2017, doi: 10.1080/00405000.2017.1308786.
A. Grosfeld-Nir, B. Ronen, and N. Kozlovsky, “The Pareto managerial principle: when does it apply?,” Int J Prod Res, vol. 45, no. 10, pp. 2317–2325, May 2007, doi: 10.1080/00207540600818203.
Sugiyono, Metode Penelitian Kuantitatif, Kualitatif dan R&D. Bandung: Alfabeta, 2017.
K. Srinivasan, S. Muthu, S. R. Devadasan, and C. Sugumaran, “Six Sigma through DMAIC phases: A literature review,” International Journal of Productivity and Quality Management, vol. 17, no. 2, pp. 236–257, 2016, doi: 10.1504/IJPQM.2016.074462.
J. De Mast and J. Lokkerbol, “An analysis of the Six Sigma DMAIC method from the perspective of problem solving,” Int J Prod Econ, vol. 139, no. 2, pp. 604–614, Oct. 2012, doi: 10.1016/J.IJPE.2012.05.035.
T. N. Goh, “A strategic assessment of six sigma,” Qual Reliab Eng Int, vol. 18, no. 5, pp. 403–410, Sep. 2002, doi: 10.1002/QRE.491.
M. J. Harry, “Six sigma: A breakthrough strategy for profitability,” Qual Prog, vol. 31, no. 5, pp. 60–64, 1998, Accessed: Nov. 25, 2023. [Online]. Available: https://www.proquest.com/docview/214756892?fromopenview=true&pq-origsite=gscholar
J. Antony, “Design for six sigma: a breakthrough business improvement strategy for achieving competitive advantage,” Work Study, vol. 51, no. 1, pp. 6–8, Feb. 2002, doi: 10.1108/00438020210415460.
J. M. Lucas, “The essential six sigma,” Qual Prog, vol. 35, no. 1, pp. 27–31, 2002.
H. Aouag, A. Kobi, and A. Mechenene, “Analysis of competitiveness level in an industrial company using a continuous improvement-based approach,” International Journal of Six Sigma and Competitive Advantage, vol. 9, no. 2–4, pp. 87–108, 2015, doi: 10.1504/IJSSCA.2015.074958.
H. B. Fakher, M. Nourelfath, and M. Gendreau, “Integrating production, maintenance and quality: A multi-period multi-product profit-maximization model,” Reliab Eng Syst Saf, vol. 170, pp. 191–201, Feb. 2018, doi: 10.1016/J.RESS.2017.10.024.
G. Q. Cheng, B. H. Zhou, and L. Li, “Integrated production, quality control and condition-based maintenance for imperfect production systems,” Reliab Eng Syst Saf, vol. 175, pp. 251–264, Jul. 2018, doi: 10.1016/J.RESS.2018.03.025.
N. Alp and J. Mau, “Quality through design: A Six Sigma approach,” PICMET 2016 - Portland International Conference on Management of Engineering and Technology: Technology Management For Social Innovation, Proceedings, pp. 2181–2187, Jan. 2017, doi: 10.1109/PICMET.2016.7806772.
DOI: https://doi.org/10.31315/opsi.v17i1.7107
Refbacks
- There are currently no refbacks.
Sekretariat :
Jurusan Teknik Industri
FTI UPN "Veteran" Yogyakarta
d.a Jalan Babarsari 2 Tambakbayan Yogyakarta 55281
Telp. (0274) 486256
Website http://jurnal.upnyk.ac.id/index.php/opsi
email : jurnal.opsi@upnyk.ac.id
indexed by:
 |  |  |  |
 |  |  |  |
 |
This work is Licensed Under a Creative Commons Attribution 4.0 International license.
View My Stats