Quality Control in the Automotive Component Electroplating Process Service Industry with the DMAIC and FMEA Approaches
DOI:
https://doi.org/10.20961/performa.v25i2.3974Keywords:
DMAIC, FMEA, DPMO, Six Sigma, ElectroplatingAbstract
This research aims to identify main causes of product defects in electroplating process at PT. X, an automotive component manufacturing company, and formulate improvement proposals to enhance product quality. Approach used is Six Sigma-DMAIC (Define, Measure, Analyze, Improve, Control) combined with Failure Mode and Effect Analysis (FMEA) method. Initial research was conducted by identifying types of product defects. Measurement results showed a Defects Per Million Opportunities (DPMO) value of 18909 with a sigma value of 3,59, indicating that quality was within industry average levels and required improvement. Pareto analysis revealed that a dominant defect was dirtiness, contributing 37,7%. Through cause-and-effect analysis and FMEA, main factors causing dirtiness were operators not installing dummy plates, suboptimal rinsing processes, dusty environments, and material and machine contamination. Highest Risk Priority Number (RPN) of 560 confirmed that human factors were the main cause of defects. Proposed improvements include installing dummy plates, adding a rinsing process, cleaning the transporter machine, closing the production area, and using clean gloves and work clothes. The implementation of these improvements proved to be effective, reducing the DPMO to 9583, increasing sigma to 3,84, and reducing dirty defects from 12% to 2,25%. Results of research prove how combining DMAIC and FMEA could significantly improve product quality. These findings can be used as a reference for implementing continuous improvement in electroplating services and other manufacturing sectors facing similar problems
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