Improving Material Efficiency on Calendering Process by Using Six Sigma and Define Measure Analyze Improve Control (DMAIC) Methods in Indonesian Leading Truck Bus Bias Tire Manufacturer

Abstract

Companies continue to make efficiency efforts when running their business. Cost of Poor Quality (COPQ) is one of the company parameters in making efficiency. In order to suppress COPQ, increasing material efficiency needs to be done. This research aims to design a method to improve material efficiency in the calendering process of a tire manufacturing company. The method design is carried out by implementing Six Sigma and Define Measure Analyze Improve Control (DMAIC) as the main framework and several tools to support each stage. Increasing efficiency focuses on the problem of appearance treatment that is incompatible with the type of scrap that can be prevented. At the end of this study, the main factor of the nonconforming appearance of treatment is machine, method, and materials. The control to keep the improvement is by using work instructions and checksheet. Improvements to the root of the problem provide an increase in material efficiency by 23.07% in quantity and financial, and the sigma level there is shifting 0.089 to 4,178 in cord calendering process.