Reducing defect products in instant noodles production with Six Sigma

Quality control is an essential thing in running a company, especially in the production process. The resulting product is inseparable from failure or nonconformity, as is the case experienced by Indofood (M) Food Industries Sdn. Bhd. It has a defect rate of 2.84% of instant noodle product scrap, which occurs in the middle of the production process, resulting in waste and loss. The purpose of this research includes the DMAIC (Define, Measure, Analyze, Improve, Control) approach, which is to define problems experienced by the company, measure current quality conditions, analyze things that cause product defects, provide solutions to overcome the causes of these problems and calculate design control measures. The results of this research indicate that the company’s quality conditions from April to September 2018 suggest that the process does not meet specifications and must be improved even though the average sigma value produced has reached 4.24. The results show that three types of defects were found as the main contributor to the problems, namely dirty crushed, finely crushed, and broken crushed. The root cause of the problems was based on personal factors (operator problem), work method factors (process standard problem), and machine factors (machine problem), respectively.