Improve quality remanufacturing welding and machining process in indonesia using six sigma methods

Welding and machining processes for Lift Arm Repair in Remanufacturing heavy-duty companies in Indonesia has produced parts according to customer specifications, but the company still has the intention to reduce the level of damage and Cost of Poor Quality. The purpose of this study is to demonstrate the application of the Six Sigma method with the DMAIC cycle (Define, Measure, Analyze, Improve and Control). Other tools to analyze this problem are the Pareto Diagram and the Cause and Effect Diagram. The level of product defects in the Lift Arm Remanufacturing process is relatively high, namely 73.5% over the past 5 months with the categories of Miss Alignment (68.5%), Porosity (18.9%), Crack (4.5%), Oversize (2.7%) Scratches (2.7%) and Others (2.7%). with a value of 834586.47 DPMO and is at 1.91 sigma with a COPQ of Rp.650,800,000.00. The Six Sigma approach with the DMAIC method is a systematic method that focuses on improving processes. From the DMAIC method, it can be known the factors that cause defect miss alignment and porosity through the cause diagram. After Six Sigma implementation, the level of defective products decreased from 73.5 to 7.03% with an increase in quality from 1.91 to 2.43 Sigma. Finally, we can reduce COPQ from IDR 650,800,000 to IDR 135,000,000 or 66.47% from the previous condition. © 2020 Lavoisier. All rights reserved.