Volume 5, Issue 8, August – 2020 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Green Quality Improvement Using Six Sigma Method

Sutrisno Harianto Ellysa Nursanti
Master Degree Program in Industrial Engineering in Lecturer in Industrial Engineering Department, Postgraduate
National Institute Of Technology (ITN) Program National Institute of Technology (ITN)
Malang, Indonesia Malang, Indonesia

Abstract:- Traditional cast brass handicrafts Majapahit [2],[3]. Brass craft industry SMEs are required to pay
is one of the nation's cultural heritage which has a high attention to the surrounding environment in production
historical value. The uniqueness and quality become the process and produce products that are safe and consumeable
hallmark of this craft products. The results of by consumers.
handmade products such as sculptures, wall hangings,
souvenirs, ornaments doors and so on. To increase the II. DESCRIPTION SYSTEM
sales of traditional handicrafts of brass castings,
required Majapahit applicative technical efforts in The production process of making Majapahit brass cast
improving the quality of products which are eco- sculpture in Bejijong village is still traditional using simple
friendly. Quality improvement method such as Six equipment. The production system begins with the making
sigma. Six sigma focuses on decreasing flawed rate, by of the master mold and preparation of raw materials, then
reaching the standard 3, 4 flawed in a thousand the casting process is carried out, then the cooling process
possibility. Six sigma has 5 phases; define, measure, and removal of the cast sculpture from the mold, as well as
analyze, improvement, and control. In this research, six the finishing and coloring process.
sigma is applied in producing cast brass handicraft
starting from making the master mold, preparation of Green quality improvement or green quality
smelting raw materials, cooling process, releasing of the improvement is now very popular with consumers. This is
mold, and finishing. Purposefully to improve the quality shown by the greater awareness of consumers to get
by overcoming and decreasing the high of flawed products that are feasible, safe and environmentally friendly.
possibility and also applying marketing mixture in Consumers are willing to pay more for products that do not
improving the market segmentation of traditional cast damage the environment or are environmentally friendly.
brass of Majapahit market. The result is quality
improvement is shown by decreasing happen in number This change in consumer awareness results in large
of flawed product in total of mean for about 154, 8 and small industries indirectly having to pay attention to the
decreased to 59,5. While the calculation of the six sigma, environment and take responsibility not to damage the
flawed product of cast brass handicraft is for about environment. The product produced is not only feasible and
1,7625 sigma value or being in level 2 and increased to safe but in the production process it must be cleaner and
3,725 or being in level 4 with the flawed possibility in more environmentally friendly.
amount 235,000 for thousand times of production. The
ability of production for the requirement which is The biggest obstacle faced by craftsmen in an
wanted by the consumers and owning a good enough environmentally friendly production process is the absence
capability but still needed some correction to achieve of definitive work operating standards. To meet the quality
world class home industry of national and international standard products that are
environmentally friendly, it requires an applicable
Keywords:- Defect, Green Quality Improvement, Six Sigma, standardization of production processes so that quality
Traditional Brass Casting Craft. standards can be achieved.

I. INTRODUCTION III. METHODOLOGY

The craftsmen traditional Majapahit cast brass joined The production process of making Majapahit brass
in a ganesha cooperative formed in 2005. The quality of sculptures still using traditional equipment. The production
eco-friendly improvement or green quality improvement is system begins from making the master mold and preparation
now very popular for consumers [1],[2],[3]. It is shown by of raw materials, the casting process is performed, then
the greater awareness of consumers to obtain an adequate, cooling process and the release of sculptures cast from the
safe, and eco-friendly product. Consumers are willing to pay mold, as well as finishing and dyeing processes.
more for eco-friendly products [4].
The production process of making Majapahit brass cast
Changes in consumer awareness has led to large and is still traditional using simple equipment. The production
small industries indirectly must pay attention to the system begins with the making of the master mold and
environment and are responsible for not harming the preparation of raw materials, then the casting process is
environment. Resulting product is not only feasible and safe carried out, then the cooling process and removal of the cast
but in the production process must be clean and eco-friendly

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Volume 5, Issue 8, August – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
sculpture fromthe mold, as well as the finishing and coloring Factor causes of these defects are caused and are
process. directly related to humans, machines, methods, materials,
and environment [5]. Work shown in Figure 2 Fishbone
The brass cast craftsmen are incorporated in the diagram.
Ganesha cooperative that was formed since 2005.
Researchers are very interested in the traditional brass cast
of Majapahit because until now it is still survive in modern
era. From the results of preliminary observations obtained
the average sales data of brass cast craftsmen which came
from the members of the Ganesha cooperative for one year.

From the survey results in the field of data in general

the total production is 3,000 units to 1,239 units the number
of defective products. After doing research in the field of
product defects, can be broadly categorized types of defects
were found to be four types: defects or perforated holes
,disability rats, rough surface defects and disability cracks.
The research stages can be seen in Figure 1 below:

Fig 2:- Fishbone Diagram

Product defect repair process to define a process

improvement process model needs to be known to be used,
namely Suppliers - Inputs - Processes - Outputs - Customers
shown in Figure 3.

Fig 1:- Research Stage Fig 3:- Suppliers-Inputs-Processes-Outputs-Customers

IV. RESUTS AND DISCUSSIONS Suppliers - Inputs - Processes - Outputs - Customers

diagram illustrates the process becoming the focus of the
The results of several previous studies are still in the project. There are five elements of this diagram are:
form of normative suggestions, there are no clear operating Supplier of raw materials such as brass collectors or trashy
standards for work, there is no standardization of processes, brass scrap materials in the surrounding craftsmen’s area.
equipment, materials and supervision. The research only Input the process is brass which had been merged in the
discusses application theory, quality improvement and sales Smelting Process. Process, Consisting of Molding,
which have no consideration to eco-friendly factors. Smelting, Casting, Cooling, Inspecting and Finishing.
Output after all stages of the process is done it will produce
Thus, this research is important to be carried out to cast brass handicraft products. Customer, Is the process of
improve the quality and sales of Majapahit's traditional brass the finished product to the customer.
cast products which are eco-friendly. By increasing human
resources, standardizing processes, equipment, materials and A. Counting Defect Per Unit and Defect Per Million
supervision, eco-friendly production efficiency can be Objects
achieved. Before calculating process capability, first calculate the
value of Defect Per Unit [6]-[7]. Defect Per Unit calculation
Based on observations and interviews with cast brass is to give a general idea of the number of defects that occur
craftsmen joined in cooperative direct Ganesha, the most every unit. In this study, the unit is categorized brass casting
dominant cause of the product defect occurs in: the process product, so that the meaning Defect Per Unit is the number
of making a master mold, raw material melting process, the of defects that occur in every cast brass products. Defect Per
process casting. Unit value calculation is generally obtained from a simple

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Volume 5, Issue 8, August – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
calculation, the number of defects divided by the total The following is a comparison of the number of
number craft production of cast brass. defects that occur in every cast brass products shown in
Table 1.

No. Total Production Total Disability Defect Per Unit Defect Per Million Objects Sigma value

1 250 106 0.424 424 000 1.65

2 250 97 0,388 388 000 1.75
3 500 234 0.468 468 000 1.55
4 500 229 0.458 458000 1.65
5 500 244 0,488 488 000 1.55
6 250 75 0.3 300000 2.05
7 250 69 0,276 276000 2.05
8 500 185 0.37 370000 1.85
mean 375 154.875 0.3965 396 500 1.7625
a.The results of Author’s research

Table 1:- Detect Per unit and detect er million objects.

From the calculation of Table 1, it can be seen that the Development of metal-chemical coating techniques
defects of brass handicraft products reach the sigma level of brass metal coloring is still done by craftsmen of Majapahit
1.7625 or are at the level 2 sigma condition with a possible brass cast. So that the resulting colors are not evenly
damage of 396,500 for a million times the production distributed in certain parts. By using metal-chemical coating
process or 39.65% Defect Per Million Objects. techniques in addition to coating the metal it is also able to
resist corrosion of the metal. The resulting color is more
This certainly becomes a loss for craftsmen if there is no flexible and varied so that it can meet customer desires.
improvement in the production process. To reduce the level
of product damage or defects produced, it is necessary to The application of green productivity in eco-friendly
increase the level of sigma in each production process. quality improvement is laid out Waste Reduction. By
applying 3R; reduce, reuse, and recycle as an effort to
B. Improve Phase improve the quality which is eco-friendly [8],[2],[3].
The aim of the improve phase is to find and implement Suggestions of 3R’s application in cast brass handicraft in
solutions that will eliminate the cause of the problem, home industry; Reducing the using of firewood or charcoal
reduce variety process and also prevent the same mistakes in burning process changed by using gas. Reuse the remains
happen. There some ways to reach those aims for instance. of sand mold is able to be smelted and reused for the mold
of the next production. Recycle is using raw material from
 Generate Creative Ideas trash which made from brass recycled in smelted raw
This creative idea aims to develop the Majapahit material.
traditional brass cast industry, especially in the production
process. The creative ideas that are possible to do are: From the shorter time in the combustion process, the less
pollutants produced, let alone using electricity, and the
Design development and mold making this mold design environmentally friendly production process can be
is made manually, it is possible to use computer numerically achieved [9],[10],[11],[12],[13]. Development of metal-
controlled. In addition to good accuracy, the speed can also chemical coating techniques. Brass metal coloring is still
be measured so that it can save production time. done by craftsmen of Majapahit brass cast. So that the
resulting colors are not evenly distributed in certain parts.
Development of furnaces traditional burning stoves used
to use firewood as fuel. This process requires a long time in By using metal-chemical coating techniques in
heating and the heating results are also uneven. The addition to coating the metal it is also able to resist corrosion
resulting temperature cannot be stable in the heating of the metal. The resulting color is more flexible and varied
chamber often causes one of the factors causing failure in so that it can meet customer desires.
the production process. By using modern furnace commonly
used in the ceramic industry, the heat produced is stable and  Material Management
can be measured so that the perfection of the results can be Material here is the pure brass or wreckage of brass
achieved. Besides that the shorter time in the combustion which has been processed before. The function of material
process, the less pollutants produced, let alone using management is responsible in planning, sourcing,
electricity, and the environmentally friendly production purchasing, storing, and controlling [14].
process can be achieved.

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ISSN No:-2456-2165
Suggestions of material management’s application in Cast brass handicraft products offered must be able to
home industry of cast brass handicraft; planning an accurate meet consumers desires and needs. Especially in the
plan in the application of raw material depends on guarantee of product quality, and timeliness in accordance
consumers’ request. Sourcing having cooperation with brass with the order.
wreckage wholesaler for being supplier of brass. Purchasing
of raw material can be cooperating with Ganesha The price of brass craft products must be able to
cooperation as colleague of craftsman in case of fund. compete with other products on the market. By following
Storing by the limit of the land. the standard market prices both domestically and abroad.

Craftsman should have a warehouse to save the raw Place in (marketing mix) commonly referred to as
material coordinated by the cooperation. Controlling the use distribution channels, in this case from brass cast craftsmen
of raw material through the cooperation hopefully the to the hands of customers. Special delivery or express
availability of raw material is guaranteed. Preventing the package makes it easy to send or distribute products with
crisis of raw material which causes rising price of material additional shipping costs adjusted for distance.
as balancer of material price in market.
Promotion of marketing spread both directly (direct
 Marketing Mix Brass Craft Product marketing) and by using technological advances, especially
The marketing of brass cast crafts has only relied on the internet. To reach marketing to international level, you
orders from customers, especially customers who have art can use internet access or social media, for example
shops in the cities of Bali and Yogyakarta. To increase (Facebook).
sales, a system that is used in marketing (marketing mix)
[15],[16],[17] is needed, which includes:  Standardization of Brass Craft Process Acording to
MMSE
Based on a survey of good product results in SMEs
cast brass craftsmen who are members of the Ganesha
cooperative. Then it can be concluded in a standard table
[18] of production processes that can produce good products
shown in Table 2.

No Stages of production Tools or materials Process

Making master Giving oil for every five times in making
1 Cement and Silicone
mold wax molds
Sifting materials from a mixture of other
materials to produce pure metal brass for
2 Smelting raw materials Smelting furnaces and brass metal
raw materials is obtained from brass
wraps
The casting process is carried out at a
3 Casting Metal thermometer (Thermocouple) temperature of 90000 Celsius -1.0500 0
Celsius
Brass cast results are placed in an open
4 Cooling Fan (Air Cooler)
space with free air circulation
Every connecting welding process uses
5 Welding Clamping tools (Vise) clamps so the results can be precise and
even
Giving a polished green stone every time
6 Refining Grinding and Green stone
is used for five brass craft units
Stainless steel container, material for Mix all ingredients in a stainless steel
antique green color (BTC MS 040 T container and heat it to a temperature of
7 Staining
250 gram and BTC 047T 250 gram 700 0 Celsius then dip brass metal for one
for every 5 liters of water minute
b. The results of Author’s research
Table 2:- Standart Cast Brass Production Process.

Final expectation of the value of sigma after improvement for four months there was a change in the
improvement. value of sigma.

From the results of improvement, it is expected that the The following is a comparison of the sigma values of
change in the value of Sixma is better than before [28],[29]. the production process before and after improvements are
This means an increase in the value of sixma in accordance made as shown in Table 3.
with the desired expectations. After an experiment of

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Total Defect Defect
Total Disability Sigma Value
No Product Per Unit Per Million Objects
before After before After before After before After
1 250 106 52 0.424 0.208 424 000 208 000 1.65 3.55
2 250 97 43 0,388 0.172 388 000 172 000 1.75 3.65
3 500 234 80 0.468 0.36 468 000 360000 1.55 3.65
4 500 229 67 0,458 0.35 458000 350000 1.65 3.8
5 500 244 93 0,488 0.38 488 000 380000 1.55 3.5
6 250 75 21 0.3 0.84 300000 84000 2.05 4.25
7 250 69 15 0,276 0.06 276000 60000 2.05 4.4
8 500 185 74 0.37 0.262 370000 262 000 1.85 3.8
mean 375 154.8 59.5 0.3965 0.235 396 500 235000 17.625 3.725
The results of Author’s research
c.

Table 3:- Standart Cast Brass Production Process.

C. Expectations final sigma value after repair V. CONCLUSION

From the result of the expected improvement to
changes sixma better than ever. This means that an increase Application of a good standard production process
in the value of sixma according to the desired expectations. based on standard SMEs cast brass crafts men. So as to
After a four-month experiment in no change in the value of reduce the number of defective products with calculation of
sigma. the value of the rate sigma 1,7625 or are in levels 2 sigma
before the repair, with possible damage to 396,500 to one
Comparison of the sigma value of the production million times the production process. Increased to levels
process before and after improvement as shown in Table 1 sigma with the 3,725 level with possible damage to 235,500
and 2 diagram is shown by the reduction in the number of to one million times the production process after repair. so
defects of cast brass handicraft products of the mean value the statisfaction of customers can be met with the assurance
of 154,8 was reduced to 59,5. of product quality, and timeliness in accordance with the
order.
While the results of the calculation of the value of
sigma defects cast brass handicraft products from 1.7625 SUGGESTION
sigma level or set of conditions becomes 3.725 sigma level
2 or level 4 in a state with the possibility of damage by Expansion of Majapahit's brass craft market
235,000 to a million times the production process. segmentation through Ganesha cooperatives both locally
and abroad using internet technology. The Ganesha
Comparison of sigma and the mean value in the form Cooperative should actively participate in and conduct
of a diagram is shown in Figure 4 Comparison Sigma And training or workshops in collaboration with government
Mean Value [19],[20]. agencies (Disperindag) and competent private sector.

The Ganesha Cooperative should actively participate

in exhibitions at home and abroad held by government or
private agencies. Cooperative Ganesha to be active in
marketing Majapahit cast brass handicraft products in
collaboration with Artshop or star hotels

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