Reducing the nonconforming products by using the Six Sigma method: A case study of a polyes-ter short cut fiber manufacturing in Indonesia

Abstract

Polyester short cut fiber is a textile industry which is rarely explored or researched. This research explains the necessary steps of improvement using Six Sigma method to reduce the nonconforming products in a polyester short cut fiber manufacturing in Indonesia. An increased nonconforming products in the shortcut fiber production process created some quality problems from January to May, 2015. Define, measure, analysis, improve, control (DMAIC) steps were implemented to determine root cause of the problems and to improve production process using statistical approach. The results of Six Sigma improvement has indicated that the process capability was increased from 2.2 to 3.1 sigma, savings $18,394.2 USD per-month.