Analysis of Improved Product Disability Using Six Sigma Approach and FMEA (Failure Mode and Effect Analysis Method) (Case Study at Batik Komar House)

Abstract

Batik Komar House is a company that produces batik and Batik Merchandise. The main problem
with Batik Komar House is the large number of defective products. At present the product defects reach 7-
10% of total production, therefore the DMAIC method will be used to reduce the number of defects that occur.
Problem Resolution using FMEA, CTQ, Fishbone Diagrams and Pareto Diagrams, and Data Uniformity Test
to find out the problems that occur. From FMEA and DMAIC, it was concluded that the main cause of the
number of defective products was due to errors in the production process, so that the best treatment to deal
with the problem was to check regularly all production processes from suppliers of other raw materials to
finished processes, because the number of defects was felt still too high then the FMEA and DMAIC methods
will be used to look for factors that affect the quality characteristics and try to reduce the number of defects
that exist today, but after conducting data processing and analysis. From the research results obtained RPN
value on the Failure Mode of Damaged Fabric Motifs of 280, Failure Mode of Fabrics Not Appearing that is
equal to 210, Failure Mode of Night Painting on Uncluttered Fabrics of 245, Failure Mode of Color Changes
on Fabric that is equal to 216, Failure Color Decrease Mode in Fabric that is equal to 224, Failure Mode There
is Night Remaining and Starch for Fabric that is equal to 150 and Sigma Level for each Period from January
2018 - December 2018 which is 2.8-2.99 Sigma, so that there is a need to improve it is given proposed
improvements based on the quality of supporting raw materials, proposed improvements based on tools,
improvements based on methods, and proposed improvements based on the environment by controlling
standardization in batik making standards, documenting and disseminating the corrective actions so that the
failure does not recur.