Quality Control of Welding Defect at PT XYZ Using the Six Sigma Method by Integrating the DMAIC Method

This study aims to analyze and reduce welding defects at PT XYZ using the Six Sigma method integrated with the DMAIC (Define, Measure, Analyze, Improve, Control) approach and the Seven Tools of Quality Control. Welding defects are a critical issue in manufacturing industries as they increase rework and scrap costs, reduce production efficiency, and negatively impact product quality and customer satisfaction. This research adopts a quantitative case study approach. Primary data were collected through direct observation, operator interviews, and defect recording using check sheets, while secondary data were obtained from production reports and company operational documents. In the Measure phase, the analysis showed an average Defects Per Million Opportunities (DPMO) value of 25,744.185 with a sigma level of 3.44, indicating that the process is relatively stable but still requires improvement. The Analyze phase identified the root causes of defects using fishbone diagrams, revealing that the main contributing factors include human, machine, method, and material aspects. Furthermore, Risk Priority Number (RPN) analysis indicated that incorrect welding parameter settings, worn contact tips, malfunctioning jig clamps, and inaccurate teaching points are the most critical causes. Improvement strategies were developed using the 5W+1H approach, including parameter standardization, operator training, routine maintenance, and stricter process monitoring. The implementation of Six Sigma is expected to reduce defect rates, improve process capability, and support continuous quality improvement at PT XYZ.

Six Sigma, Quality Control, DMAIC

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