DMAIC application for the reduction of defect in manufacturing industry

Nik Rezali, Nik Muhammad Ibrahim (2021) DMAIC application for the reduction of defect in manufacturing industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

DMAIC is a data-driven quality strategy used to improve effectiveness and efficiency of organizational processes across industry. Nowadays, DMAIC is used to improve the quality of production output by minimize the variation, eliminate the defects, and improve the process capability. The aim of this project is to implement DMAIC (Define-Measure- Analyse-Improve-Control) methodology in a biscuit manufacturing industry to study the reduction of defects. The project follows the DMAIC methodology to systematically investigate the root cause of defects and provide a solution to reduce or eliminate them. Suitable Six Sigma tools is applied such as project charter, SIPOC diagram, pareto chart, Why-why analysis, and fishbone diagram. In particular, the Design of Experiments (DOE) techniques was combined to statistically determine whether the key process variables which is proofer temperature, oven temperature(baking), oven temperature(drying), and weight of dough, had an impact on the number of quality defects produced. From the analysis, it is found that the major contributor to the shape and size defect are the proofer temperature, oven temperature(baking) and oven temperature(drying). The causes of the machine’s temperature were identified, and action plans were implemented. Due to a Movement Control Order (MCO), a proposal was made to the Biscuit Company to implement Total Preventive Maintenance (TPM) and a new dough cutting technique. The project demonstrated that DMAIC cycle is an effective approach that can solve a defect issue using simple solutions. It has the potential to provide good returns to the company if conducted properly and efficiently.

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