Enhancing Production Quality and Sustainability in Aluminum-Based MSMEs Through Defect Reduction Using Six Sigma Methodology

Faculty of Industrial Technology, Ahmad Dahlan University, Yogyakarta, Indonesia

^* Corresponding author: muhammad.faishal@ie.uad.ac.id

Abstract

AS Aluminum, a Micro, Small, and Medium Enterprise (MSME), specializes in producing various aluminum-based products such as thick and thin cake molds, including waffle, laker, pukis, and terang bulan molds. However, the production process is hampered by high defect rates, reaching 8.26% for thick molds and 8.52% for thin molds, based on data from November and December 2022, far exceeding the company’s target of a maximum 2% defect rate. This study aims to identify the root causes of these defects and propose effective solutions to reduce their occurrence. Using the Six Sigma methodology and the DMAIC (Define, Measure, Analyze, Improve, Control) framework, the study identifies several key factors contributing to defects, including incomplete aluminum melting, the ab-sence of standardized work procedures, dirty molds, worker fatigue, limited employee skills, and low-quality raw materials. Corrective actions were implement-ed, such as the procurement of thermo scanners, the development of Standard Operating Procedures (SOPs), raw material selection, and meticulous mold cleaning. After two weeks of implementing these measures, the defect rates dropped significantly to 4.37% for thick molds and 4.83% for thin molds, demonstrating the effectiveness of the proposed improvements in enhancing production quality and efficiency.