Quality Control with Six Sigma Method to Minimize Polyester Fabric Product Defects at PT Sukuntex

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PT. Sukuntex is a textile industry that produces fabrics, which is polyester with a percentage of 58% of total production. The production system is “make to order”. The quality control division inspects every cloth manually, operator pays attention to the stretch of cloth on the inspection machine. If the defective cloth length is more than 10 meters it will be cut, then the length of the cloth target cannot be reached. The defects number also affects inspection time. To analyze defects in polyester fabric products and PT. Sukuntex can adjust its ability to control product defects, so quality control of polyester is carried out using six sigma method. The six sigma stages are DMAI (Define-Measure-Analyze-Improve) to determine DPMO value, sigma level, causes of defects, and suggestions for improvement. Based on pareto diagram, 3 dominant defects were namely thin thick, loose, and dirty oil. DPMO is 49,825.15 meters with sigma value 3.15. The causes of defects analysis using fishbone diagram with human, machine, method, and environmental factors. Efforts to improve sigma value are carried out with FMEA-AHP analysis. The results of FMEA-AHP 1^st rank are improvements for thick-thin and loose defects by tightening supervision of the fabric weaving process. The improve stage is improvement plan with 5W+1H method for each problem.