PT. ABC is a manufacturing company that produces Electric Power Steering (EPS) Housing components. For the past three months, there have been problems with the EPS production process. The problem is related to the finding of defective products which on average reached 3.9% of the total production, and has exceeded the maximum limit allowed by the company, which is 2%. This study aims to overcome these problems by making improvements using the DMAIC method in the hope of finding the root cause of the emergence of defects and making improvements to reduce the number of defects that occur. The improvement results have shown that the number of defects reduced from 3086 pcs to 1948 pcs per 22 working days or decreased by 0.54% with an increase in sigma level from 3.95 to 4.01 sigma. In this case, DMAIC implementation is effectively reduced defects by 1.5% based on the sigma level. To achieve a 6-sigma level equivalent to a world-class industry, companies must make continuous improvements by fixing other root causes.

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Application of The DMAIC Method in Improving The Quality of Electric Power Steering Housing Products

Low oil price environment impacted to business of Oil and Gas Company including PT. SDEC. However, PT. SDEC was able securing limited and fixed capital budget to drill well and had committed to drill certain well number to Government of Indonesia. When the initial 12 wells were completed with longer cycle time (average 9.9 days/well) than business plan (7.5 days/well) and also higher cost, the problem became more complex because company need to complete well as per commitment and in other hand no additional capital will be spent by parent company if actual expenditure exceeded the initial budget. Company assigned a team to solve the problem through Lean Six Sigma. Through strong collaboration among team, the project execution performance was improved (the Cp of drilling cycle time was improved from 0.06 to 1.08). As the result of this project save cost around $ 2.8 million.

https://jemis.ub.ac.id/index.php/jemis/article/download/335/251

Petrus Tri Wahyudi

Papers

Continuous improvement of drilling ultra-shallow horizontal well through lean six sigma methodology