Analysis of the Application of Lean Six Sigma Method to Improve Quality in the Paving Block Production Process at PT. XYZ
DOI:
https://doi.org/10.33506/mt.v12i2.6094Keywords:
DMAIC, Kaizen, Lean Six Sigma, Paving block, Value Stream Mapping (VSM)Abstract
Waste generated during manufacturing operations remains a significant challenge for production-based companies, including PT. XYZ, which operates in paving block manufacturing. This study aims to identify the categories and origins of waste in the production line, examine the application of Lean Six Sigma, and propose improvements to reduce waste in the paving block production process. The DMAIC framework was chosen for its capacity to combine waste elimination with variation control. Data were collected through direct observation, interviews, and documentation, supported by tools such as SIPOC Diagram, CTQ, Value Stream Mapping (VSM), DPMO, P-control chart, fishbone diagram, Kaizen Five-M Checklist, and 5W+1H. The findings identified three dominant waste categories: defects, waiting, and inventory. Out of 4,667,001 units produced, 53,949 were defective, yielding a DPMO of 2,889, equivalent to a sigma level of 4.26. Waiting waste reached 65 minutes per production cycle, with an estimated loss of IDR 18,229 per day, while inventory waste stemmed from limited temporary warehouse capacity and excess finished goods, generating an estimated opportunity cost of IDR 18,000,000 per day. Following the proposed improvements, Process Cycle Efficiency (PCE) increased from 37.45% to 43.88%. Recommendations include enhancing operator competency, scheduling routine machine maintenance, and adjusting production volume based on available warehouse capacity.
References
Abuzied, Y. (2022). A Practical Guide to the Kaizen Approach as a Quality Improvement Tool. Global Journal on Quality and Safety in Healthcare, 5(3), 79–81. https://doi.org/10.36401/jqsh-22-11
Adeodu, A., Maladzhi, R., Kana-Kana Katumba, M. G., & Daniyan, I. (2023). Development of an improvement framework for warehouse processes using lean six sigma (DMAIC) approach. A case of third party logistics (3PL) services. Heliyon, 9(4), e14915. https://doi.org/10.1016/j.heliyon.2023.e14915
Daniyan, I., Adeodu, A., Mpofu, K., Maladzhi, R., & Kana-Kana Katumba, M. G. (2022). Application of lean Six Sigma methodology using DMAIC approach for the improvement of bogie assembly process in the railcar industry. Heliyon, 8(3), e09043. https://doi.org/10.1016/j.heliyon.2022.e09043
Dwiguna, S., & Amalia, A. N. (2023). Analisa Kualitas Produk Staple Fiber Reguler Dengan Metode Six Sigma DMAIC Di PT. Asia Pacific Fibers. Metode: Jurnal Teknik Industri, 9(2), 110-123.
Eko, S., Sugiarto, A., Robiansyah, M. R., Octavianto, A., & Kurnia, H. (2026). Analisis Six Sigma untuk Mengurangi Cacat Karton pada Mesin Wraparound. Metode: Jurnal Teknik Industri, 12(1), 39-51. https://doi.org/10.33506/mt.v12i1.5092
Fathurohman, D. M. H., Purba, H. H., & Trimarjoko, A. (2021). Value stream mapping and six sigma methods to improve service quality at automotive services in Indonesia. Operational Research in Engineering Sciences: Theory and Applications, 4(2), 36–54. https://doi.org/10.31181/oresta20402036f
Fibriani, L., Garside, A. K., & Amallynda, I. (2024). Lean Six Sigma approach to improve the production process in the garment company: A case study. Journal of Engineering and Management in Industrial System, 11(2), 153–168. https://doi.org/10.21776/ub.jemis.2023.011.02.7
Gutierrez, J. M. C., Correa, M. N. M., Espinoza, J. M. V., & Cornejo, J. (2025). Lean Six Sigma for Industry 4.0 to Improve Sustainability and Supply Chain Efficiency in Manufacturing Companies: A Systematic Review. ISAS 2025 - 9th International Symposium on Innovative Approaches in Smart Technologies, Proceedings, 1–6. https://doi.org/10.1109/ISAS66241.2025.11101881
Jou, Y. T., Silitonga, R. M., Lin, M. C., Sukwadi, R., & Rivaldo, J. (2022). Application of Six Sigma Methodology in an Automotive Manufacturing Company: A Case Study. Sustainability (Switzerland), 14(21), 1–27. https://doi.org/10.3390/su142114497
Kurniawan, M. A., & Wulandari, I. A. S. (2024). Integrasi vsm dan valsat di lean manufacturing untuk kurangi waste di pt. Spln. Metode: Jurnal Teknik Industri, 10(2), 217-226. https://doi.org/10.33506/mt.v10i2.3448
Nurhayati, & Hasanah, A. N. (2022). Analisis kapabilitas proses produksi sediaan drop dengan menggunakan program statistik Minitab. Majalah Farmasetika, 7(4), 325–406. https://doi.org/10.24198/mfarmasetika.v7i4.39297
Rusnidiyanto, Rakhmanhuda, I., & Mukti Pradanarka, A. (2024). Analysis of SQDCMPE based on Lean Concepts in the Daily Workwear Production Process at PT. XYZ’s Convection Company. Journal of Research and Technology, 10(2), 207–215 https://doi.org/10.55732/jrt.v10i2.1336
Sirajudeen, R. S., & Krishnan, K. A. (2022). Application of lean manufacturing using value stream mapping (VSM) in precast component manufacturing: A case study. Materials Today: Proceedings, 65, 1105–1111 https://doi.org/10.1016/j.matpr.2022.04.159
Salwin, M., Pszczółkowska, K., Pałęga, M., & Kraslawski, A. (2023). Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools. Energies, 16(21). https://doi.org/10.3390/en16217292
Widiwati, I. T. B., Liman, S. D., & Nurprihatin, F. (2025). The implementation of Lean Six Sigma approach to minimize waste at a food manufacturing industry. Journal of Engineering Research (Kuwait), 13(2), 611–626. https://doi.org/10.1016/j.jer.2024.01.022
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2026 Jeane Angela Mariyan Ema Sigo, Kifayah Amar
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
