Analysis of Quality Control of Lightweight Brick Products Using the Lean Six Sigma Method
Analisa Pengendalian Kualitas Produk Bata Ringan Menggunakan Metode Lean Six Sigma
DOI:
https://doi.org/10.21070/ups.10623Keywords:
Lean Six Sigma, DMAIC, Quality Control, Lightweight Bricks, Product DefectsAbstract
The lightweight brick manufacturing industry continues to face quality challenges, reflected in a 4% defect rate of total production. This study aims to identify the factors causing product defects and determine their root causes to develop data-driven improvement strategies. The research applies the Lean Six Sigma methodology with the DMAIC (Define, Measure, Analyze, Improve, Control) framework. Data were obtained through field observations, interviews, and analysis of production records from May to October 2025. Eight defect types were identified, including cap cracks, dimensional nonconformities, incomplete cutting, chipped edges, collapse, cutting cracks, separating cracks, and collapse/EH minim, with dimensional issues being the most dominant at 22%. Root causes are linked to human factors, machine conditions, methods, materials, measurement, and environment. The process shows a DPMO of 4,812.67 and a sigma level of 4.09, indicating the need for continuous improvement through operator training, SOP standardization, machine maintenance, and enhanced quality control.
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