Volume 5, Issue 1, January – 2020 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Decreasing Analysis of Reject Claim Plate Levels of

Shocking on Insert to Cassette Process for
Battery YTZ4V Type Using Dmaic and
Benchmarking Approachmethod
Case Study in Process Battery Manufacturing Industry
Fidin Saptaaji, Nur Sarva Jayana, Aris Setyo Radyawanto, Akhyar Zuniawan
1
Industrial Enginering, University of Mercubuana. Jakarta
2
Industrial Enginering, University of Mercubuana. Jakarta

Abstract:- Strict industrial competition in particular Total Internal Eksternal reject

Battery manufacturing is always competing to improve Amount of reject 2016 ( claim ) 2016/
the quality of a product and reduce as much as possible Type Production (PPM ) (PPM )
reject claim market. So this research will focus on this YTZ
key action improvement by using DMAIC approach Series 6662075 6300 41.7
method which has been known as the most effective YTX
problem solving method and has been widely used by Series 3394517 7100 35
many previous research. The research design used is Table 1
explorative quantitative type focusing on 4M analysis to Source: Production data
find the cause of the problem and find the solution.
Starting with step 1: Define, through the collection of Since the customer claim is far from the specified
data sampling month of Jan-Dec 2016 known that reject target and can affect the customer's trust then this research
claim of Plate bent is 41 PPM Step 2: Measure, focuses on the decrease of Claim costumer. From the data if
Processing data reject and the amount of claim reject battery claims for type YTZ have a reject value of 41.7 ppm
and set the target that will do the improvement 3: so that researchers focus to reduce reject claim type YTZ
Analyze , benchmarking against type cassette A and battery Series
Cassette B from FTA analysis Step 4: Improve, define
and standardize Cassette Type cassette B dimensional This research will use DMAIC approach method with
changes by changing the partition edge L and edge R benchmarking process in step analysis. According to
from C3mm to R4mm from Cp = 1.58, Cpk = 0.63 to Cp Guangyu Mu et. al. (2013) using the DMAIC six sigma
2.32 and Cpk 2.23. Step 5: Control, After getting the methodology approach to decrease the defect in the welding
dimension set value 29.5 PPM down to 4 PPM with exhaust system process in the automotive company and the
target standard 18 PPM and decrease to company cost result of defect rate biting edge and stomata decreased
savings of 455.5 KUSD / Year. 20000 ppm to 1280 ppm and the sigma level can be
increased from 3.55 to 4.52. And Gupta (2016) implements
Keywords:- Battery Manufacturing, Plate bent, Six sigma, the DMAIC six sigma model to evaluate and improve the
Benchmarking, FTA, Cost Saving,Reject. quality of the chassis preparation process in the amplifier
production process. From the study conducted to increase
I. INTRODUCTION the sigma level of 3.35 to 3.58 from the process preparation
chassis.
In the process of making the battery there are parts -
parts that consists of the terminal, plate group, container,
water acid, lid cover of the component is very important
role in the quality and performance of a battery is in the
Plate group with this company is very focused to reduce
and make continuous improvements to lower reject claim
market caused by bent plates. The result of the reject type
YTZSeries battery has a reject rate of 41.7 PPM in 2016
compared to the Type YTX series of 35 PPM. Here reject
example of bent palte.

Fig 1:- Reject Plate bent

Source: Production Data 2017

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 Formulation of the Problem  Defect Major
Based on the background described above, then the Defect major is a defect category with a high degree
formulation of the issues to be discussed in this study are: of seriousness or commonly called the term scrap. Products
 Looking for factors that cause reject plate bent? with this major category can not be done anymore in the
 What actions should be taken to reject the bent plate sense that the product must be discarded / can not be sold.
down?
 What is the decrease in cost saving to reject claim According Feigenbaum (Jha& Kumar, 2010), quality
customer after the repair? is full customer satisfaction (full customer satisfaction). A
product is said to be qualified if it can give full satisfaction
 Purpose and benefits of research to the consumer, that is in accordance with what is expected
The purpose of this study is expected to: by consumers of a product.
 Determining factors causing reject plate bent
 Determine the action to be taken to lower the bent reject (Muis, 2014). In the application of quality control by
plate using DMAIC or Define method, Measure, Analyze,
 Knowing the value of cost saving from decreasing reject Improve, Control.
claim reject plate bent.
(Rimawan, 2010) Six Sigma is a business process that
 Benefit Researchers can make companies drastically increase their profits by
increasing and monitoring daily business activities by
 Scientific Contribution
Based on the review of the literature, this research minimizing waste and resources along with increasing
provides suggestions to the effort to gain knowledge of the customer satisfaction.
The goal of Six Sigma itself is not to improve quality to a
implementation of quality improvement to reduce the
Reject on Battery industry by considering all the criteria of level even though increasing quality and efficiency is the
result of the Six Sigma itself.
quality improvement process from previous research.
 Applicative Contributions
(Rimawan, 2009) Improving business performance
This research is expected to make the input on the
requires a structured approach, disciplined thinking, and the
company as the object of case study and as a model for
involvement of all employees in the company. These
quality improvement for other companies in terms of
factors have been the basis of various methods of increasing
decreasing the number of Rejects to the bent plate and
productivity and quality over the years. The implementation
decreasing the reject claim caused by bent plates.
of Six Sigma methods is carried out at the DMAIC (Define,
Measure, Analysis, Improve, Control) and Cost of Poor
 Assumptions and Problem Restrictions
Quality at the calculate from product print defects.
In doing this research that focuses on the reduction of
bent reject plate because it can cause short between cells
 Define
and not included in the specification of the number of
This phase is divided into 3 parts:
voltages and amperes on the battery that is :
 Prepare and initialize project charter
 Plate group in the process of assy, the process of
The background of the project charter consists of a
entering plate group is done with tools insert to
business case, problem statement, statement of purpose,
container that has been specified by the standard process
scope, schedule, list of advantages, list of rules of conduct
in the company and the process does not move the
and responsibility, and outline of the project objectives.
machine / station at the time of its production
 Limit tolerance The bent plate did not change during the
 Conducting SIPOC analisas (Suplier, Input, Process,
study mass.
Output, Customer)
 The machine in the Assembly has not changed or
It is a simple way to identify suppliers and their inputs
modified on the pusher system.
to the process, process sequence, process output, and
 Type of battery type in meticulous has not changed the supplier importance to output.
design during the research
 Analyzing VoC (Voice of customer)
II. LITERATUR REVIEW VoC analysis aims to identify issues related to Critical
to Quality (CTQ) for market segments. There are 2 types of
(Burhan 2015 ). Defect is a condition in which a VoC data that is reactive and proactive. Reactive data types
product declared failed in achieving the requirements set by ignore data sources while proactive data are sourced from
the company or customer. Defect itself is grouped into
within organizations that specialize to collect such data
several categories among them :
through wawacara, surveys, market research, customer
research, benchmarking and focus on groups or segments.
 Defect Minor Quality tools used in the define phase include:
This minor defect is a defect category with a low level
CE-Matrix, Pareto chart, SIPOC.
of seriousness. Product with this minor defect category can
still be done again (reworks) to achieve the specified
requirements

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 Measure  Define the problem and boundary condition of the
The phase measure is divided into 4 main parts, system
namely:  Reconstruction of the fault tree
 Making operational definitions for each CTQ (Critical  Identify minimum cut set or minimum path set
to Quality)  Qualitative analysis of the fault tree
 Designing measurement system validation for each  Quantitative analysis of fault tree
CTQ
 Designing capability limits for each CTQ
 Check phase checklist

Quality equipment used in this phase:

 R & R Gauge
 Graph (Control chart, run chart, histogram, etc.)
 Process capability analysis (Cp, Cpk)
 Analyze
Kulaitas equipment used in this phase:
 Test the hypothesis
 Graphic technique (control chart, histogram, runchart,
etc)
 Correlation and regression
 Cause effect matrix
 Improve
The purpose of phase up is:
Fig 2:- Symbol - symbol FTA
 Make and make sure the solution choices
Source: Rachman 2016
 Focus KPIV to optimize output
 Generate and ensure Y = f (x)
B. Metode Benchmarking
(Budi Kho, 2016) The Benchmarking process is an
The equipment used in this phase is: outward looking process (other products, other
 DOE (Design of Experiment) organizations, other systems) to find out how others reach
 ANOVA their level of performance and understand the work
 Hypothesis testing processes they use. Thus, Benchmarking can explain what
 Correlation and regression is going on behind the performance of either process or the
product being compared. If properly implemented,
 Control Benchmarking can assist an organization in improving its
It is the last operational stage in an effort to improve organizational performance or production process.There are
quality based on Six Sigma. At this stage the quality 4 important stages in implementing Benchmarking
improvement results are documented and disseminated, the
best practices that are successful in improving the process  Understand in detail the current production process or
are standardized and disseminated, the procedures are product.
documented and made as standard guidelines, and  Analyze production processes or other products that
ownership or responsibility transferred from the team to the perform well.
owner or person in charge of the process.  Compare the production process or the product itself
with a production process or a product that performs
A. FTA Method( fault tree Analysis ) well.
Rachman, (2016) Techniques to identify failures of a  Apply the necessary corrective steps to approach the
system using FT (fault tree) perform analysis by utilizing production process or the product performing well.
FT either qualitatively or quantitatively. FTA (Fault Tree
Analysis) is function-oriented or better known as the "top In his explanation, Robert Camp in his book published
down" approach because this analysis starts from the in 1989 put forward a Benchmarking Methodology
system level (top) and passes it down. The starting point of consisting of 12 Stages, namely:
this analysis is to identify the functional failure mode at the  Selecting Subject
top level of a system or subsystem. FTA is a widely used  Determining the Process
technique for studies dealing with the risks and reliability of  Identify potential Partners to compare
a system engineering. Potential events that cause failure  Identify data sources
from an engineering system and the probability of  Collect data and select partners to compare
occurrence of the event can be determined by FTA. A TOP  Determine the gap
event which is the definition of a system failure, must be  Establish process differences
determined first in the FTA.  The expected performance targets
 Communicating

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 Goal Adjustment  Process Benchmarking,namely benchmarking that
 Apply compares work processes.
 Review and re-adjust  Functional Benchmarking,namely Benchmarking that
performs a comparison on certain Functional work to
C. Type of Benchmarking improve the operational on the functional.
Benchmarking can be done Internally comparing the  Performance Benchmarking, namely benchmarking
performance of several groups or teams within the that compares performance on a product or service.
Organization or Externally comparing the performance of  Product Benchmarking,namely Benchmarking that
an organization with other organizations or between compares the product competitors with their own
Industries. Benchmarking can be divided into several types, products to determine the location of strength (Strength)
such as: and weakness (Weakness) products.
 Financial Benchmarking, namely Benchmarking that
 Strategic Benchmarking,namely Benchmarking which compares the financial strength to determine its
observes how other people or organizations outperform competitiveness.
their competition.

III. METHODOLOGY

DMAIC Stages Analisis data Quality Tools

Define 1. Identify the flow of production Pareto

processes.
2. Identify for the problem to be analyzed
Measure 1. Create a control chart to control the Pareto, U chart, FTA
number of defects that occur.
2. Creating the dominant type of defect
category in the insert to cassette process
improvement
DMAIC Stages Analisis data Quality Tools

Analyze 1. More in-depth analysis of factors FTA, 5W +1 H

causing defects in the insert to casstte process
and minimizing the risk of failure

Improve Use the design factorial Banchmark

1. Design standard cassette tools
2. Modified cassette design
Control Controlling the process and standardizing the Drawing, SOP
cassette design against bent defect plat

Table 2

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Fig 3:- Flow Chart of research methods

IV. CONCLUSION

 Define Stage (Defined)

At the stage of data collection, the data - data collected include everything associated with data processing. Data obtained by
collecting claim market data

QTY CLAIM QTY SALES PPM Target ( PPM )

Jan-16 10 278031 35.96721 18
Feb-16 11 295864 37.17924 18
Mar-16 12 222006 54.05259 18
Apr-16 10 324887 30.77993 18
May-16 13 295422 44.00485 18
Jun-16 13 331947 39.16288 18
Jul-16 12 290723 41.2764 18
Aug-16 8 226670 35.2936 18
Sep-16 11 212337 51.80444 18
Oct-16 12 230728 52.00929 18
Nov-16 11 263327 41.77316 18
Dec-16 11 238297 46.16088 18
FY2016 134 3210239 41.74144 18
Table 3
Source : Company data

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Based on the Type YTZ product seriesnya following contributors largest reject claim according to the following pareto
diagram:

Pareto Chart of Type Battery

140
100
120
80
100

Jumlah Reject 60

Percent
80

60
40
40
20
20

0 0
Type Battery YTZ 4V YTZ 6V YTZ 7V YTX7 Other
Jumlah Reject 79 23 16 12 4
Percent 59.0 17.2 11.9 9.0 3.0
Cum % 59.0 76.1 88.1 97.0 100.0

Fig 4
Source : Data though 2017

 Measure
From the results Data processing on the number of claim market and target production limit of 18 PPM.

Fig 5
Source : Data though 2017

The data shows the number of rejects in 2016 in January to December 2017 (YTD) of 41.74 PPM (Part per million). In early
January to April 2017 a very significant increase of 46 PPM. That caused by several types of rejects are as follows:

Jenis defect claim market YTZ4 V

140
100
120
80
100

60
Percent

80
C2

60
40
40
20
20

0 0
C1 Plate bengkok Kurang Elektrolite Proses COS
C2 79 48 7
Percent 59.0 35.8 5.2
Cum % 59.0 94.8 100.0

Fig 6
Source : Data though 2017

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Of the three types of damage, the largest reject contributor is bent plate sebnayak 59% compared with less electrolyte as
much as 48% and COS process 5.2%. The results of these researchers continue the analysis of the causes of the reject plate bent

 Analyze( Analys )

 Benchmarking type Defect Plate bent from Customer

FTA ( Fault tree Analysis ) Insert To Cassette
From the results of the analysis using FTA to determine the improvement and the root of the problem against the bent plate is
makadi described as follows :

Fig 7:- FTA Diagram The insert to cassette process

Source: Data 2017

A. Benchmak Operator expertise ( Skill Operator)

From the test results skil operator researchers make benchmarking against 2 people or operators who have been accustomed
or devoted to the station process insert to cassette for 5 working days between the shift 1 and shift 2.

Test Benchmarking
No Operators Shift Standard SOP Result
H1 H2 H3 H4 H5
1 A Shift 1 1. Plate group positions are neatly arranged √ √ ● √ √ OK
2. Plate group is not blocked √ √ √ √ √ No effect
3. There should be no crooked earplugs √ √ √ √ √ to the process
4. There should be no plate folding √ √ √ √ √
2 B Shift 2 1. Plate group position is arranged neatly √ ● √ √ √ OK
2. Plate group is not blocked √ √ √ √ √ No effect
3. There should be no crooked earplugs √ √ √ √ √ to the process
4. There should be no plate folding √ √ √ √ √
3 B Shift 1 1. Plate group position is arranged neatly √ √ √ √ √ OK
2. Plate group is not blocked √ √ √ √ √ No effect
3. There should be no crooked earplugs √ √ √ √ √ to the process
4. There should be no plate folding √ √ √ √ √
4 A Shift 2 1. Plate group position is arranged neatly √ √ √ √ ● OK
2. Plate group is not blocked √ √ √ √ √ No effect
3. There should be no crooked earplugs √ √ √ √ √ to the process
4. There should be no plate folding √ √ √ √ √
Table 4
Source : Company data

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From the data for the thickness of plate group measured in accordance with the standard dimensions set by the company, the
position of the curve is at the target limit. Dimensionally shows that there is no deviation dimension. Next look and gemba to the
production to meninjaui and verify the state of the engine insert to cassete following data on the results of gembaproduction :

B. Position Guide insert to cassette against cassette

Table 5
Source: Gemba March 2017 data

From the results of production to the insert to cassette positioning of the cassette machine in the centering position did not
change, including the pressure on the water cylinder pusher of 0.5 Mpa according to 2017 production standard.

Fig 8:- Machine Insert to cassette against cassette

Source : Picture 2017

C. Test of Palte Group Capability

Fig 9
Source : Data though 2017

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Fig 10
Source : Data though 2017

From the measurements to the dimensions of the cassette width indicates type A the value of Cp 2.32 for Cpk 2.23 is very
good for the width dimension almost closer to the target. However type A type cassette can be categorized in suaian pas

Fig 11
Source : Data though 2017

From the measurements to the dimensions of the cassette width indicates the B type of the nilaCp is nice but Cpk<1.33
denotes there is a shift towards the minimum size (LSL) or tendency even though Cassette type B dimension enters but the
tendency towards the forced force. From the results of both types of cassettes for type B suaian forced category so that given the
same pressure type cassette B hard to enter and potentially bent Plate because it is not strong to resist the impetus of the pressure

D. Condition Cleaning Cassette

Fig 12:- Cleaning Schedule Cassette (Blasting tools)

Source: 2016 production report

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From production report data that cleaning cassette already done in 1 month done every 2 weeks but reject trend during
january month - April 2017 still found reject on plate bent .

Fig 13:- Data Cleaning cassette against reject claim

Source: 2017 processed data

 Improve ( Repair )
 Determine the Alternative repair steps
From the results of data analysis following alternatife improvement on cassette design

Fig 14:- Alternative Solution

Source: Data 2017

Alternative solution taken from 5w + 1H is to modify the cassette in this way the work more time and cost efficiency that
dikerluarkan by the company because fewer compared with having to buy new cassette

Table 6
Source : Company data

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 Control
 Control by Cassette Design Standard
Having obtained the results of the analysis test, Alternative cassette design that needs to be done is standardization tools,
especially on the cassette in the following partition.

Fig 15

Table 7
Source : Data though 2017

From these data needs to be made design changes and in standarkan. In order to make the new cassette tool or spare not use
the old design with C3mm suduh that can cause the occurrence of plate bent

 Make standard SOP steps

To prevent the Production Dept. make standard checks at the beginning of each production to ensure that the cassette in the
production line uses the latest R4mm dimensional design that has been preserved by the company. After the design changes on the
Edge R and edge L in the cassette and determined the results of improvements to the bent plate can be seen from May 2017 to
2014 des decreased significantly from the total 41.7 PPM and in januari 2017 - April 2017 of 29.5 PPM Became 4 PPM target
claim is reached. Under 18 PPM.

Fig 16:- Graph of the result of improvement

Source: 2017 production data

After the design changes on the Edge R and edge L in V. CONCLUSION

the cassette and determined the results of improvements to
the bent plate can be seen from May 2017 to 2014 des It can be concluded that this study which takes time
decreased significantly from the total 41.7 PPM and in from data collection jan 2016 until april 2017 for analysis
januari 2017 - April 2017 of 29.5 PPM Became 4 PPM and see data amount of reject plate bent. From this result
target claim is reached. Under 18 PPM. we can see the improvement of the design of the R and L
edge partition changes on cassette B from the original C3
mm to R 4mm to produce the capability index of dimension
Cp 2.32 and the value of Cpk 2.23. in accordance with the

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