Enhancing Automotive Part Quality in SMEs through DMAIC Implementation: A Case Study in Indonesian Automotive Manufacturing
Abstract
Purpose: The purpose of this study is to reduce defects and improve the quality of automotive parts at SMEs by implementing the define, measure, analyze, improve, and control (DMAIC) stage of Six Sigma.
Methodology/Approach: The application of the DMAIC method was carried out in an automotive component manufacturing company in Indonesia that produces Stay B Muffler Protector HC21 as a research object. The cause of the high number of product defects is known at the define stage. In the measure stage, details from field data are collected and sigma levels are determined.
Findings: The results of the improvement actions taken have an impact on the DPMO value and an increase in the sigma level. DPMO value decreased by 19,891 from 22,230 to 2,339. Meanwhile, the sigma level increased by 0.82 from 3.51 to 4.33. To control the sigma level, it is proposed that improvement be carried out by making work instructions for the use of spot welding tools so that it can be standardized, controlled continuously, and make continuous improvements.
Research Limitation/implication: Limitations of this study may include limitations in covering all aspects of production or other factors that may affect product quality.
Originality/Value of paper: The originality of this paper lies in the application of the DMAIC method of Six Sigma in the context of automotive manufacturing SMEs in Indonesia.
References
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Sumasto, F., Maharani, C.P., Purwojatmiko, B.H., Imansuri, F. and Aisyah, S., 2023a. PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry. Indonesian Journal of Industrial Engineering & Management, 4(2), pp.87–98. https://doi.org/10.22441/ijiem.v4i2.19527.
Sumasto, F., Nugroho, Y.A., Purwojatmiko, B.H., Wirandi, M., Imansuri, F. and Aisyah, S., 2023b. Implementation of Measurement System Analysis to Reduce Measurement Process Failures on Part Reinf BK6. Indonesian Journal of Industrial Engineering & Management, 4(2), pp.212–220. https://doi.org/10.22441/ijiem.v4i2.20212.
Sumasto, F., Satria, P. and Rusmiati, E., 2022. Implementasi Pendekatan DMAIC untuk Quality Improvement pada Industri Manufaktur Kereta Api. Jurnal INTECH Teknik Industri Universitas Serang Raya, 8(2), pp.161–170. https://doi.org/doi.org/10.30656/intech.v8i2.4734.
Bebeteidoh, O. and Takim, S.A., 2015. Manufacturing defects in the automobile industry, a case study of the remote causes and effects of Toyota‟s transmission malfunctions in cars. International Journal of Engineering and Applied Sciences (IJEAS), [online] (2), pp.2394–3661. Available at:
Brun, A. and Milano, P., 2014. DMAIC Six Sigma Definition and an Analytical Implementation: Car Industry Case Studies. International Journal of Engineering Research & Technology, 3(8), pp.653–666.
Condé, G.C.P., Oprime, P.C., Pimenta, M.L., Sordan, J.E. and Bueno, C.R., 2023. Defect reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier. International Journal of Quality & Reliability Management. https://doi.org/10.1108/ijqrm-05-2022-0157.
Daniyan, I., Adeodu, A., Mpofu, K., Maladzhi, R. and Kana-Kana Katumba, M.G., 2022. Application of lean Six Sigma methodology using DMAIC approach for the improvement of bogie assembly process in the railcar industry. Heliyon, [online] 8(3), p.e09043. https://doi.org/10.1016/j.heliyon.2022.e09043.
Duc, M.L., Bilik, P. and Truong, T.D., 2022. Design of Industrial System Using Digital Numerical Control. Quality Innovation Prosperity, 26(3), pp.135–150. https://doi.org/10.12776/qip.v26i3.1747.
Gomes, F. da S., Camargo, P.R., da Motta Reis, J.S., Diogo, G.M.M., Cardoso, R.P., de Barros, J.G.M., de Souza Sampaio, N.A., Barbosa, L.C.F.M. and Santos, G., 2022. The Main Benefits of Application of Six Sigma for Productive Excellence. Quality Innovation Prosperity, 26(3), pp.151–167. https://doi.org/10.12776/qip.v26i3.1712.
Guleria, P., Pathania, A., Shukla, R.K. and Sharma, S., 2020. Lean six-sigma: Panacea to reduce rejection in gear manufacturing industry. Materials Today: Proceedings, [online] 46, pp.4040–4046. https://doi.org/10.1016/j.matpr.2021.02.559.
Henny, H., Andriana, I., Latifah, A.N. and Haryanto, H., 2019. The Application Lean Six Sigma Method Approach to Minimize Waste. IOP Conference Series: Materials Science and Engineering, 662(2). https://doi.org/10.1088/1757-899X/662/2/022089.
Karthik, M., Halesh, S.B. and Hanumanthrayagouda, M.B., 2019. Reducing the Rejection & Improving Productivity of Pistons. International Journal of Innovative Science and Research Technology, 4(1), pp.81–85.
Kosina, J., 2015. Shainin methodology: An alternative or an effective complement to six sigma? Quality Innovation Prosperity, 19(2), pp.18–31. https://doi.org/10.12776/qip.v19i2.580.
Lin, X., Chen, B. and Xie, H., 2012. Study on principle of product defect identification. Procedia Engineering, [online] 43, pp.393–398. https://doi.org/10.1016/j.proeng.2012.08.068.
Mantrala, M.K., Seetharaman, P.B., Kaul, R., Gopalakrishna, S. and Stam, A., 2006. Optimal pricing strategies for an automotive aftermarket retailer. Journal of Marketing Research, 43(4), pp.588–604. https://doi.org/10.1509/jmkr.43.4.588.
Nallusamy, S., Nivedha, R., Subash, E., Venkadesh, V., Vignesh, S. and Vinoth Kumar, P., 2018. Minimization of rejection rate using lean six sigma tool in medium scale manufacturing industry. International Journal of Mechanical Engineering and Technology, 9(1), pp.1184–1194.
Neeru, Rajput, N.S. and Patil, A., 2023. Reducing Oil Leakage in Heavy Duty Transformers Made in Small-Scale Manufacturing Industry Through Six Sigma DMAIC: A Case Study for Jaipur. Evergreen, 10(1), pp.196–211. https://doi.org/10.5109/6781070.
Pereira, A.M.H., Silva, M.R., Domingues, M.A.G. and Sá, J.C., 2019. Lean six sigma approach to improve the production process in the mould industry: A case study. Quality Innovation Prosperity, 23(3), pp.103–121. https://doi.org/10.12776/QIP.V23I3.1334.
Razak, I. and Nirwanto, N., 2016. The impact of product quality and price on customer. Journal of Marketing and Consumer Satisfaction, 30(2012), pp.59–68.
Rifqi, H., Zamma, A., Souda, S.B. and Hansali, M., 2021. Lean manufacturing implementation through DMAIC approach: A case study in the automotive industry. Quality Innovation Prosperity, 25(2), pp.54–77. https://doi.org/10.12776/qip.v25i2.1576.
Ruben, R. Ben, Vinodh, S. and Asokan, P., 2017. Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: a case study. Production Planning and Control, [online] 28(15), pp.1193–1211. https://doi.org/10.1080/09537287.2017.1357215.
Sharma, J., Tyagi, M., Bhardwaj, A. and Walia, R.S., 2023. Factors Assessment for Encumbering the Implementation of Sustainability Based Lean Six Sigma Practices in Food Supply Chain. Evergreen, 10(1), pp.379–388. https://doi.org/10.5109/6781097.
Sharma, R., Gupta, P. and Saini, V., 2018. Six Sigma Dmaic Methodology Implementation in Automobile Industry: a Case Study. Journal of Manufacturing Engineering, [online] 13(1), pp.42–050. Available at:
Silalahi, A.S.F., 2014. Indonesia Kondisi Industri Manufaktur Indonesia Dalam Menghadapi Globalisasi. Jurnal Ekonomi & Kebijakan Publik, 5(1), pp.1–14.
Stylidis, K., Wickman, C. and Söderberg, R., 2015. Defining perceived quality in the automotive industry: An engineering approach. Procedia CIRP, [online] 36, pp.165–170. https://doi.org/10.1016/j.procir.2015.01.076.
Subburaj, M., Prabhakaran, S. and Prabhuram, T., 2010. Implementation of DMAIC principle -six sigma technique on road safety. Proceedings of the International Conference on Frontiers in Automobile and Mechanical Engineering - 2010, FAME-2010, pp.368–372. https://doi.org/10.1109/FAME.2010.5714861.
Sumasto, F., Maharani, C.P., Purwojatmiko, B.H., Imansuri, F. and Aisyah, S., 2023a. PDCA Method Implementation to Reduce the Potential Product Defects in the Automotive Components Industry. Indonesian Journal of Industrial Engineering & Management, 4(2), pp.87–98. https://doi.org/10.22441/ijiem.v4i2.19527.
Sumasto, F., Nugroho, Y.A., Purwojatmiko, B.H., Wirandi, M., Imansuri, F. and Aisyah, S., 2023b. Implementation of Measurement System Analysis to Reduce Measurement Process Failures on Part Reinf BK6. Indonesian Journal of Industrial Engineering & Management, 4(2), pp.212–220. https://doi.org/10.22441/ijiem.v4i2.20212.
Sumasto, F., Satria, P. and Rusmiati, E., 2022. Implementasi Pendekatan DMAIC untuk Quality Improvement pada Industri Manufaktur Kereta Api. Jurnal INTECH Teknik Industri Universitas Serang Raya, 8(2), pp.161–170. https://doi.org/doi.org/10.30656/intech.v8i2.4734.
Authors
Sumasto, F., Arliananda, D. A., Imansuri, F., Aisyah, S., & Purwojatmiko, B. H. (2023). Enhancing Automotive Part Quality in SMEs through DMAIC Implementation: A Case Study in Indonesian Automotive Manufacturing. Quality Innovation Prosperity, 27(3), 57–74. https://doi.org/10.12776/qip.v27i3.1889
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