Reducing waste on wheat flour packaging: an analysis of Lean Six Sigma

Reducing defects in the process of packaging wheat flour is important to be done continuously. This study aims to identify and measure the activity of waste that occurred, performance sigma value, and obtain solutions which do by the researcher in Consumer Packing Division PT Z. Waste is measured and assessed using the methods of Lean Six Sigma and Failure Mode and Effect Analysis (FMEA). Based on research, activity categorized waste activities include Defect, Waiting, Non-Utilizing People's Talent, Transportation, and Motion. Measurement focused on the largest waste Defect is Broken Pack. The result showed the defect per million opportunities (DPMO) value 4089.2475 with level sigma 4.14 and capability process (Cp) 1.31. FMEA showed eight causes factors of the failure broken pack. Four failure mode of which exceeds the critical value that is less of a response operator (Risk Priority Number or RPN=150), lack of control of packaging (RPN=126), less-skilled workers (RPN = 120) and the inaccuracy of allocating the number of workers (RPN=105). Therefore, on the job training, proper allocation of workers during breaks, the packaging audit of the suppliers, and increase the number of workers needed to support the packaging efficiency of wheat flour.