Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Quality Control Analysis Using Six Sigma Method to

Reduce Post Pin Isolator Riject in Natural
Drying Pt Xyz
Doddy Agustiandi1), Sugiyono Madelan2), Ahmad Badawi Saluy3)
Magister Manajemen
MercuBuana University, Bekasi, Indonesia

Abstract:- This study aims to analyze the product failure is a method for implementing and managing overall quality
of the type of pin post insulator product, as well as to improvement activities in an organization (Usman).
find the main cause and to propose improvements at PT
XYZ using the Six Sigma method. This research was Many researchers have previously researched quality
conducted only in parts of the production process that control using the Six Sigma (DMAIC) method in various
have a high failure rate such as in natural industries but only a few have researched quality control
dryingsections. This study uses a Six Sigma methodology using the Six Sigma method in the ceramic insulator
approach with tools such as Fishbone diagrams and industry. Previous researchers explained the application of
Pareto diagrams. This research is a quantitative Six Sigma in the water industry (Didiharyono,
descriptive exploratory method. The results of this study Marsal&Bakhtiar, 2018), the application of six sigma in the
were the type of cracked lip crack caused by the vaccum electronic goods industry, namely the Blue-Ray Disc Player
is unstable in finishing section, with the improvement of (DonyAriefWidiatmoko), the application of six sigma in the
cleaning the vaccum duct and routine maintenance car painting industry (Mohhamed A Rahman, AKM
vaccum duct in finishing machine. For the type of Mohiuddin&Hanani Abdullah, 2015), the application of six
cracked middle skirt crack caused by the auger on sigma in the construction industry (Molly Thomas
pugmill machine being worn, between the dimensions of &I.Porcia, 2017).
Honggote (HG) in the forming and Sita in finishing are
not matching, with corrective actions: repairing pugmill This study will analyze any failures in the production
machine, vaccum duct in finishing section, repairing sita section of pin post ceramic insulators, as well as find the
so that HG and sita are matched and conducting routine main causes of the failure of the product and provide
test and periodic maintenance. The conclusion of this suggestions for its repair. This research is also to determine
research is that quality control using the six sigma the value of SQL (Sigma Quality Level) in the
method can reduce the rejection level and increase the productionnatural drying section of pin post ceramic
six sigma level. insulators.

Keywords:- Six Sigma, Quality Improvement, Fishbone II. THEORETICAL REVIEW

Diagram, and Ceramic Insulator.
A. Control
I. INTRODUCTION Control is a process by which managers monitor and
regulate how an organization and all its members carry out
This company is one of the industries in the industrial the activities needed to achieve organizational goals
sector in the field of medium voltage ceramic insulators, efficiently and effectively (Jones and George, 2003).
namely the production of 22 kV pin post insulators.In April
2020, the company had a Pin Post production failure in the B. Quality
sections natural drying is 2.49% and the company also Juran (1995) defines three qualities that are used,
targets a rijek level for the natural drying at 0.5%. Thus it is namely:
necessary to control product quality to achieve production 1. Quality is the specialty of a product that answers
defect targets. consumer needs.
2. Quality is free from defects
Researchers chose quality control using Six Sigma 3. Quality is compatibility with the intended use.
because "Six Sigma is a new management tool used to
improve Total Quality Management, very focused on quality
control by exploring the company's overall production
system which aims to eliminate production defects" (SHIFT
Indonesia, 2017). Six Sigma is considered better than other
methods such as Total Quality Management (TQM), TQM

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
C. Defect Data collection techniques using interviews with
Good quality according to the manufacturer is if the several employees in the drying section of nature,
product produced by the company is in accordance with the observation (direct observation) and documentation. The
specifications determined by the company, while bad quality samples in this study were all internal reports on the
is if the product produced does not comply with the production section of ceramic insulator pin post in the
predetermined standard specifications and results in a natural drying section. In analyzing and calculating data
damaged product (Wahyu, 2009). using the six sigma calculator and the minitab18 application.

D. Six Sigma-Introduction and overview IV. RESEARCH RESULTS

At the end of 1970, Dr. Mikel Harry, a senior engineer
at Motorola's Government Electronics Group, started an There are five stages of DMAIC as a characteristic of
experiment to solve the problem using statistical analysis. Six Sigma, and these five phases have been implemented by
Using Motorola's GEG is starting to show dramatic the Motorola company (George, et al., 2004), including:
improvements: products are designed and produced faster at
less cost. He then wrote this method in a paper entitled "The 1. Define Phase
Strategic Vision for Accelerating Six Sigma Within The purpose of this step is to clearly define the
Motorola", Dr. Mike Harry was then assisted by Richard problem and what the impact of the problem is on customer
Schroeder, a former Motorola executive, to develop a data- satisfaction, stakeholders, employees and organizational
driven change management concept. The result of this probability.
collaboration is a simple quality measurement tool, which
later became a philosophy of business progress, known as a. Process Flow
Six Sigma. Figure 1 shows a production process flow diagram,
namely a diagram showing the general flow of the process
Six sigma is a management tool used to replace Total and equipment of a pin post ceramic insulator plant.
Quality Management (TQM) which is very focused on
quality control by exploring the company's overall b. SIPOC Diagram
production system (AchmadSutawijaya& Lenny Figure 2 shows a diagram of SIPOC (Supplier, Input,
Nawangsari, 2019). The six sigma method has been widely Process, Output and Customer), which is a tool for
applied in order to improve performance, such as the identifying the flow of raw materials, machinery, production
manufacturing industry (Linderman, et al., 2003), health and processes, finished product output until the receipt of goods
safety (Rimantho&Cahyadi, 2016; Sanjit, et al., 2011), by the customer for the natural drying section.
environmental management systems (Calia, et al., 2009).
c. Critical to Quality (CTQ)
III. METHODOLOGY Critical To Quality (CTQ), namely the requirements of
QC to achieve customer satisfaction so that there are no
The research methodology used in this research is a complaints from the previous process. Table 1 shows the
case study research with the aim of describing the Critical to Quality (CTQ) production of pin post ceramic
application of Six Sigma to the ceramic manufacturing insulators in the natural drying section. Table 2 and Figure 3
industry in natural drying section. This study uses primary show the definition of the defect type of the product.
data, namely data that is directly obtained and collected in
the research area, such as: the condition of the materials d. Identification of Problems
used, work instructions and data of employees who work in In data collection and problem identification, data was
the production department, while secondary data is data obtained in April 2020, there were products that failed in the
obtained from indirect sources that have been previously production of pin post in some parts of natural drying by
made. and used for research processes such as: process flow 2.49% and the company targeted a rejuvenation level value
data and employee competency matrices. of 0.5%. Thus it is necessary to control the quality of
production so that the level of production defects can meet
the target value of rejection.

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

(Source: Data processing company, 2020)

Fig1 :Process Flow of Making Ceramic Pin Post Insulator

(Source: Data processing company, 2020)

Fig 2 :SIPOC diagram produces Pin Post ceramic insulator in Natural Drying section

Table 1: CTQ natural drying section

Table 2 :Defect Definition Table

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
No Code Name Reject Definition
1 Form Reject form The flak from forming because the shape does
forming not match the image on the leg (tilted leg / dent)

2 Slip Slip When it is formed by the finishing machine, the

finishing knife stops halfway when it forms.

3 RA Cracked Head Cracks at the edge of the upper leaf for the
marking part of the pin post
4 RBR Cracked Lip The crack in the middle arch in the skirt from the
Skirt pin post
5 RRT Crack Middle The crack in the center of the radius in the skirt.
Skirt
6 RRA Top Radius The crack in the first neck from the top of the
Crack pin post
7 RK Cracked Legs Crack the base of the leg of the pin post
8 KTR Dirt Dirt sticking to the pin post surface but the dirt
comes from the burning kiln.

9 RD1 1st Leaf Crack That is, the cracked edge of the first leaf
10 RD2 2nd Leaf Crack Namely the crack at the edge of the second leaf

11 RL1 1st Neck Crack The crack in the first neck from the top of the
pin post
12 RL2 2nd Neck The crack in the second neck from the top of the
Crack pin post
13 PB Broken Body That is, the pin post is split in two, between the
leg and the body or between the first neck and
the second neck with the feet
14 RDR Crack In Skirt Cracks in the radius in the skirt, into the body
(sideways and not in the middle of the radius)

15 LM Laminate Cracks in the body of the pin post. The fractions

looked twisted
16 SOMPEL Sompel That is a small fraction in a certain part of the pin
post
17 PUNTIRAN Twist The twisted fracture of the leg due to the forming
/ pugmill
18 TB Paste Material The remaining material that sticks during the
forming process (usually attached to the inside
of the pin post skirt)
19 PK Broken leg The pinpost leg was broken with the body and
skirt
20 PL1 1st neck Fracture of the first neck from above the pin
fracture post as a result of mechanical stress
21 PL2 2nd neck Fracture in the second neck from the top of the
fracture pin post as a result of mechanical stress
22 C.GLZ Spot without glaze or insert small objects on the
glaze layer and small holes. Where the provision
is that the total glaze defect area in each insulator
unit must not exceed:
mm2
And every single glaze defect must not exceed:

mm2

D = largest diameter of the insulator

F = The creepage distance of the insulator
So for pin posts, the total glaze defects must not
exceed:
100 x 170 x 534/2000 = 4539 mm2
And every single glaze defect must not exceed:

50 x 170 x 534 / 20000 = 226,95 mm2.

(Source: Data processing company, 2020)

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
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Table 4 : Project Chapter

(Source: Data processing company, 2020)

Fig 3 :Types of Pin Post defects (Source: Data processing company, 2020)
Table 3 :Production data of pin post insulators in April 2020 2. Measure Phase
April 2020 The measure phase consists of finding and executing
Bagian Proses Total produksi Rijek % Rijek Target Rijek the data that has been collected to establish the basics of
Natural Drying 21.556 532 2,47 0,50% improvement and measuring the CTQ as the target process
(Source: Data processing company, 2020) and calculating the sigma level value.

e. Project Chapter a. Production Control Chart

The Project Charter is: A formal statement on the To create a control chart and binomial capabilities of
"business issue" of the Project Sponsor and a summary each production section, researchers used the help of the
document that allows all stakeholders to review the project Minitab 18 application. Figure 4: shows the control chart
and commit to supporting it.Table 4 shows the project and capabilities in the finishing, natural drying, oiling,
charter and goal statement. combustion and routine test sections.

(Source: Data processing company, 2020)

Fig 4 :control chart and capabilities in the finishing, natural drying, oiling, combustion and routine test sections.

b. Calculating the Sigma Leve Table 6 :The six sigma calculation results table
In calculating the value of DPO and DPMO using Proses DPO DPMO Level Sigma
historical data for April 2020, which shows the capability of Natural Drying 0,024679904 24679,904 3,47
the process before repair.Measurement of the six sigma level (Source: Data processing company, 2020)
with the help of the six sigma calculator application.Table
6.shows the results of the calculation of DPO, DPMO and
six sigma level.

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
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3. Analyze Phase a. Analysis capabilities
Analyze phase is the stage of isolating the main cause Comparison of process performance after repair with
of the focused CTQ, therefore determining the root of the specified requirements and before repair can be seen in
problem using the Pareto diagram and the source of the Appendix 2.
cause of the defect using a fishbone diagram.
b. Calculates the six sigma level
a. Pareto Diagram Calculation of the six sigma level is done again to
Figure 4: shows the Pareto diagram of the natural determine the achievement of the six sigma level and
drying section. From the figure, it can be seen that the main improvement is carried out again. Table 7 shows the results
failure is RBR (Cracked Skirt Lip). of the calculation of the six sigma level after the improve
stage.

From the table, it is found that the results of the

improvements that have been made can reduce the DPMO
value, in the natural drying section from 24679.9 to 3800.6.
Meanwhile, there was an increase in the sigma value, in the
natural drying section from 3.47 to 4.17.

V. CONCLUSIONS AND SUGGESTIONS

A. Conclusions
Based on the results of the research that has been done,
it can be concluded that:

(Source: Data processing company, 2020) In the finishing part, rijek occurs: RRT (middle skirt
Fig 4 :Pareto diagram parts of natural drying section. crack) and RBR (skirt lip crack), caused by: the pugmill
machine is worn out, Vaccum in the finishing section is
unstable and the Honggote (HG) radius in the forming
b. Fishbone Diagram section does not match the Sita radius in the finishing
To find the main causes of product failure, direct section. The corrective actions are as follows: cleaning the
interviews were conducted with sources who were vacuum lines in the finishing section and keeping them
considered to be experts, then a Fisbone Diagram was made. clean from material dirt, repairing the auger by patching the
Brainstroming was conducted to determine the possible root worn auger and periodic maintenance and repairing Sita in
causes from the fishbone diagram. The figure in appendix 1 the finishing section so that the radius matches the HG in the
shows a fishbone diagram of a natural drying section. forming section.

4. Improve Phase The use of the Six Sigma method has a positive effect
Analyzing the problem and taking corrective action to on the quality of the products produced. This is indicated by
reduce pin post insulators using 5W1H tools (Why, When, increasing the six sigma level from 3.47 to 4.17.
Who, Where, What and How). Table 6 shows the 5W1H
table. B. Suggestions
There are several suggestions that can be put forward
5. Control Phase in this research and are likely to have an impact on both the
In the Control stage, the selected solution is company and the industrial world, including:
implemented, with the aim of controlling the process whose  Suggestions for companies to continue research to
performance has been improved and maintaining that achieve a higher level of six sigma or zero defects by
performance.Table 7 shows the control measures to maintain increasing employee competence in implementing Six
the changes made in the improve phase. Sigma.
 The need for further research into departments other than
production for continuous improvement.

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Volume 6, Issue 1, January – 2021 International Journal of Innovative Science and Research Technology
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Table 6.Tabel 5W1H

(Source: Data processing company, 2020)

Table 8 :The table is the calculation result of DPO, DPMO

and six sigma level after the upgrade stage.
Table 7 : Table control after improvement Proses DPO DPMO Level Sigma
Natural Drying 0,003800601 3800,601 4,17
(Source: Data processing company, 2020)

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APPENDIX 1

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APPENDIX 2

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