Improving quality for plate assembly of drum brake using six sigma method

• Main Authors: Rinawati, Dyah Ika, Andini, Anggitta Realiza, Sari, Diana Puspita
• Format: Conference Proceeding
• Language: English
• Subjects: Assembly; Brake drums; Braking systems; Cylinders; Disc brakes; Drum brakes; Kaizen; Motorcycles; Six Sigma
• ISSN: 0094-243X; 1551-7616
• DOI: 10.1063/1.5112407

A manufacturer of brake system located in Jakarta, Indonesia, produces drum brakes and disk brakes for automobile as well as master cylinders and disc brakes for motorcycle. One of the products is 4-wheel drum brakes that are used in several car brands. There are 22 types of 4-wheel drum brake, which different for each type of car. Based on the collected data, non-conforming products of plate assembly on the CED Painting Line exceed the company’s target of 13. 43% of the total monthly production. The high level of non-conforming products causes loss of time and money. This study aims to improve quality performance of the product using Six Sigma included phases of define, measure, analysis, improve, and control (DMAIC). There are 2 types of non-conforming most commonly found, i.e. bubble with percentage 82.03% and spots paint/orange peel with percentage 11.24%. In measure phase, DPMO of product is measured by the value of 54.330 with the sigma value of 3.103σ. after analysis phase, 12 solutions were proposed to solve problems. To assure continuity of the improvement, some control strategies were planned i.e. (a) reward and punishment system, (b) routine checking, (c) routine briefing, (d) conduct supplier evaluation regarding the quality, and (e) Implement Kaizen event.