Kartika Nur 'Anisa' (1), Dwi Prima Rachmalia (2), Muniroh Muniroh (3)
General Background: Inconsistency in product quality due to process variation remains a challenge in many companies, impacting production efficiency and customer satisfaction. Specific Background: Similar problems often occur in the packaging industry in Indonesia. with product defect rates exceeding the 4% limit. Knowledge Gap: Previous study has focused mostly on using Six Sigma to improve product quality, but the integration of FTA and cost analysis has been limited. Aims: This study was conducted to analyse defect causing factors, analyse the cost of defective products, and evaluate the effectiveness of improved solutions in improving product quality. Result: The main findings show five main defect types i.e. hole in the sack defect, skewed stitching defect, melted sack defect, skipped stitching defect, and fuzzy sack defect, primarily caused by operator inattention, incorrect machine settings, and equipment malfunctions. After implementing, the defect rate decreased by 1.33% (9,894 units), and the sigma level increased from 3.98 to 4.11. This improvement generated cost savings of IDR 12,408,451. Novelty: Integration of Six Sigma, FTA, and cost analysis not only provides recommendations for improvement but also offers an analysis of the financial impact on the company. Implication: This study provides strategies for improving productivity and business sustainability through the reduction waste, cost savings, and the strengthening of practical field practices.
Highlights:
Keywords: Six Sigma, Defect, Reduce Waste, Cost Analysis, Woven Bag
[1] A. Tejaningrum, “Relationship of total quality management to quality product and corporate performance,” Malaysian E-Commerce Journal, vol. 4, no. 1, pp. 20–23, Apr. 2020, doi: 10.26480/MECJ.01.2020.20.23.
[2] D. Alifio Hartono and S. Sumiati, “Analysis of defect reduction in bone screw production using Six Sigma and TRIZ methods,” Indonesian Journal of Innovation Studies, vol. 26, no. 4, pp. 1–12, Jul. 2025, doi: 10.21070/IJINS.V26I4.1583.
[3] M. A. Sadikin, “Defect reduction in the manufacturing industry: Systematic literature review,” International Journal of Industrial Engineering and Engineering Management, vol. 5, no. 2, pp. 73–83, Dec. 2023, doi: 10.24002/IJIEEM.V5I2.7495.
[4] M. Zacharias, “The importance of quality control for the success of a company,” Asian Journal of Logistics and Management, vol. 1, no. 2, pp. 99–106, Dec. 2022, doi: 10.14710/AJLM.2022.16787.
[5] Rusindiyanto, I. Nugraha, and H. Syaifullah, “Identification of factors causing wood defects in furniture product material (flooring) using the Fault Tree Analysis method at PT. ABC,” Nusantara Science and Technology Proceedings, vol. 2023, pp. 195–204, Dec. 2023, doi: 10.11594/NSTP.2023.3628.
[6] Y. Keke, V., V. Putrianto, M. B. Azzuhri, E. P. Perwitasari, and Y., “An analysis of quality control on defective products at PT. Signore,” in KnE Social Sciences, pp. 827–841, May 2023, doi: 10.18502/KSS.V8I9.13396.
[7] M. Zenovjeva and R. Balvočiūtė, “The concept of a product defect, its causes and theoretical aspects of management,” Applied Sciences Research, vol. 1, no. 2, pp. 39–48, Oct. 2022. [Online]. Available: https://ojs.svako.lt/TMT/article/view/60
[8] S. K. Fadhil, “The extent of the impact of quality costs on the efficiency of financial performance: An applied study in the Iraqi Company for the Manufacture and Trade of Cartons (IICM),” World Economics and Finance Bulletin, vol. 13, pp. 1–8, Aug. 2022. [Online]. Available: https://scholarexpress.net/index.php/wefb/article/view/1222
[9] R. S. Hutapea, S. N. Dewi, and C. M. Lasambouw, “Quality costs in improving the efficiency production costs,” in Proceedings of the International Conference on Applied Science and Technology on Social Science, vol. 544, pp. 535–540, Apr. 2021, doi: 10.2991/ASSEHR.K.210424.105.
[10] F. K. Prima, A. Nurhasansyah, F. Rizal, H. Maksum, and F. Ashar, “The impact of quality control implementation on productivity and product quality in industry,” PaperASIA, vol. 40, no. 4B, pp. 52–58, Jul. 2024, doi: 10.59953/PAPERASIA.V40I4B.158.
[11] S. A. Rais and A. S. Cahyana, “Defect analysis & solution through revolutionizing recycled paper production,” Indonesian Journal of Innovation Studies, vol. 25, no. 3, pp. 1–11, Jun. 2024, doi: 10.21070/IJINS.V25I3.1163.
[12] Y. T. Jou, R. M. Silitonga, M. C. Lin, R. Sukwadi, and J. Rivaldo, “Application of Six Sigma methodology in an automotive manufacturing company: A case study,” Sustainability, vol. 14, no. 21, pp. 1–27, Nov. 2022, doi: 10.3390/SU142114497.
[13] G. Suman, D. R. Prajapati, and J. R. Kashyap, “Analysing the benefits of Lean and Six Sigma for myocardial infarction patients: A case study of an Indian hospital,” International Journal of Six Sigma and Competitive Advantage, vol. 15, no. 2, pp. 186–205, Mar. 2024, doi: 10.1504/IJSSCA.2024.145398.
[14] K. Ezewu, S. O. Emumena, and M. E. Amagre, “DMAIC approach to using confidence intervals to assess conformance and reduce variation in net weight for a manufactured product: A case study,” International Journal of Six Sigma and Competitive Advantage, vol. 15, no. 1, pp. 1–18, Jul. 2024, doi: 10.1504/IJSSCA.2024.139597.
[15] A. S. Krishna, B. S. Sikarwar, and R. K. Phanden, “Optimisation of defects using quality circle approach by QCFI India: A manufacturing case study of heat exchanger for automobiles,” International Journal of Six Sigma and Competitive Advantage, vol. 15, no. 2, pp. 130–152, Mar. 2024, doi: 10.1504/IJSSCA.2024.145383.
[16] M. H. Sajjad et al., “Waste reduction of polypropylene bag manufacturing process using Six Sigma DMAIC approach: A case study,” Cogent Engineering, vol. 8, no. 1, pp. 1–22, Jan. 2021, doi: 10.1080/23311916.2021.1896419.
[17] A. Erdıl, “Accomplishments and contributions of the Six Sigma approach for the sustainability of service and manufacturing industries in terms of quality improvement,” Research Journal of Business and Management, vol. 8, no. 3, pp. 167–180, Sep. 2021, doi: 10.17261/Pressacademia.2021.1449.
[18] H. Ghelani, “Six Sigma and continuous improvement strategies: A comparative analysis in global manufacturing industries,” International Journal of Scientific Research in Management, vol. 11, no. 8, pp. 954–972, Aug. 2023, doi: 10.18535/IJSRM/V11I08.EC05.
[19] Y. Xie and Y. Dong, “Research on Six Sigma in the service industry,” Frontiers in Business, Economics and Management, vol. 19, no. 2, pp. 17–20, May 2025, doi: 10.54097/AYFYFS67.
[20] M. F. Anggamawarti, P. Pratikto, and Y. Sumantri, “The application of Six Sigma–DMAIC method to reduce defects and improve the cartridge case process in an ammunition company,” Journal of Engineering Management and Industrial System, vol. 10, no. 1, pp. 50–59, May 2022, doi: 10.21776/ub.jemis.2022.010.01.5.
[21] S. Widjajanto and H. H. Purba, “Six Sigma implementation in Indonesia industries and businesses: A systematic literature review,” Journal of Engineering Management and Industrial System, vol. 9, no. 1, pp. 23–34, May 2021, doi: 10.21776/ub.jemis.2021.009.01.3.
[22] G. N. Sutaria, “Impact of statistical process control for continuous quality improvement in micro, small and medium enterprises,” Journal of Information Systems Engineering and Management, vol. 9, no. 4s, pp. 561–568, May 2024. [Online]. Available: https://www.jisem-journal.com/index.php/journal/article/view/11462/5328
[23] F. R. Izzati and D. S. Donoriyanto, “Analysis of product quality control using FTA (Fault Tree Analysis) method,” International Journal of Economics Development Research, vol. 5, no. 1, pp. 1758–1772, Jan. 2025. [Online]. Available: https://e-journal.uac.ac.id/index.php/iijse/article/view/5713/2357
[24] A. Sutanto, N. T. Putri, T. Alqii, and S. M. Yusof, “A solution approach on reducing defects in Batik Tanah Liek production process of a small and medium-sized enterprise,” Jurnal Optimasi Sistem Industri, vol. 23, no. 2, pp. 266–282, Jan. 2024, doi: 10.25077/JOSI.V23.N2.P266-282.2024.
[25] S. Nasir Ahmad and P. K., “Critical success factors for international development projects in Afghanistan: An exploratory factor analysis,” Journal of Project Management, vol. 7, no. 4, pp. 217–228, May 2022, doi: 10.5267/J.JPM.2022.5.001.
[26] E. P.-E. George, C. Idemudia, and A. B. Ige, “Strategic process improvement and error mitigation: Enhancing business operational efficiency,” International Journal of Engineering Research and Development, vol. 20, no. 7, pp. 210–222, Jul. 2024. [Online]. Available: https://www.ijerd.com/paper/vol20-issue7/2007210222.pdf
[27] H. Hazmi, A. Fauzi, and R. N. Sari, “Apllication of Six Sigma and FMEA methods to improve the quality of laminated tube packaging,” Journal of Artificial Intelligence and Engineering Applications, vol. 4, no. 2, pp. 1037–1043, Feb. 2025, doi: 10.59934/JAIEA.V4I2.804.
[28] E. Rizkiyah, H. Supriyanto, K. P. Dharaka, L. Grace, and I. Rahmaningtyas, “Waste analysis of the international delivery service process using Lean Six Sigma in logistics service provider companies,” Journal of Applied Engineering and Technological Science, vol. 6, no. 1, pp. 262–280, Dec. 2024, doi: 10.37385/JAETS.V6I1.5792.
[29] A. Sahin, “Root cause analysis of quality issues in watch manufacturing using Ishikawa and Pareto diagrams,” Archives of Engineering Knowledge, vol. 10, no. 1, pp. 18–23, Jan. 2024, doi: 10.30657/AEK.2024.10.4.
[30] Sunarto and H. Santoso, Buku Saku Analisis Pareto, 1st ed. Magetan, Indonesia: Prodi Kebidanan Magetan, Poltekkes Kemenkes Surabaya, Jun. 2020. [Online]. Available: https://sunartoyahya.wordpress.com/wp-content/uploads/2020/06/buku-saku-analisis-pareto.pdf