STRATEGI PENGURANGAN PRODUK CACAT PADA PENGELASAN PROJECT BAHADOPI DENGAN MENGGUNAKAN METODE SIX SIGMA STUDI KASUS DI SALAH SATU PERUSAHAAN DI CILEGON

Abstract

This study aims to formulate defect reduction strategies in the welding process of the Bahodopi Project at a company in Cilegon using the Six sigma approach. Welding is often a critical point in determining product quality, where various types of defects can significantly impact the final result. The research was conducted using a descriptive qualitative approach based on inspection data collected over 16 weeks, and data analysis was carried out through the DMAIC stages (Define, Measure, Analyze, Improve, and Control). The analysis revealed that the most dominant defects were porosity, cluster porosity, spatter, and undercut, with the main root causes being human and method factors. A five-week simulation of improvement showed a significant reduction in DPMO, from 26,500 to 4,900, and an increase in sigma level from 3.12 to 4.03. Based on the fishbone and pareto diagrams, several defect reduction strategies were formulated, including retraining of welding operators, strengthening SOP implementation, enhancing visual supervision, and conducting regular maintenance of welding machines. This research is expected to serve as a reference for improving welding quality and minimizing defects in future fabrication projects.