Design of proposed improvement of calendering process on cotton carded 24S production at PT XYZ with the DMAI approach

PT. XYZ is a company engaged in the field of Textile and Textile Product (TPT) which focuses on the dyeing process. Based on data obtained from January 2017 – June 2019 so there is 11 months of production exceeded the defect tolerance, while the tolerance was set at 2% by the company. So, it can be assumed that the process has not proceeded properly. One of the process stages on produce cotton carded 24S is the calendering process. This research is focusing on providing a proposed improvement plan for the calendering process with the DMAI approach. The first stage is the Define stage, which identifies the Critical to Quality product, Process Flow, Critical to process so that the requirements that have not been met can be identified. The second stage is the Measure stage which calculates the performance of the production process, and it is resulting the sigma level for the Cotton Carded 24S product is 4.496 sigma. The third stage is the analysis stage using several tools such as Fishbone Diagrams, 5 Why’s, and continued by calculating the Risk Priority Number (RPN) on the Failure Mode Effect Analysis (FMEA). The fourth stage is the Improve stage where the proposed improvement is designed based on the Risk Priority Number. The design of the proposed improvements to the calendering process is carried out in an integrated manner, namely making a steam temperature warning alarm system, work instructions with visual displays, and check sheets for Zigar tools.