Title: Improving Woven Bag Product Quality Using Six Sigma Methodology: A Case Study at PT Indomaju Textindo: A Case Study at Maju Jaya Textile Ltd.
Authors: Naniek Utami Handayani and Isna Diah Komisatun
Volume: 9
Issue: 7
Pages: 43-57
Publication Date: 2025/07/28
Abstract:
In response to increasing quality demands and market competitiveness, this study applies the Six Sigma DMAIC methodology to evaluate and improve quality control in the production process of woven plastic bags (woven bags) at Maju Jaya Textile Ltd., a medium-scale textile manufacturer in Indonesia. The study aimed to identify dominant defect types, determine their root causes, and propose structured quality improvement initiatives. A quantitative and qualitative approach was employed, involving direct field data collection from 81,078 units over 43 production rolls. Tools used included control charts, DPMO and Sigma level calculations, Pareto and Fishbone diagrams, Failure Mode and Effects Analysis (FMEA), and the Five M Checklist. The findings revealed a defect rate of 3.668%, with "weak weaving" identified as the most frequent defect, primarily caused by material inconsistencies and improper machine settings. The calculated Sigma level indicated that the process was below optimal capability. FMEA and root cause analysis identified key areas for improvement in raw material control, operator training, and equipment maintenance. These results align with previous research on Six Sigma applications in textile SMEs and validate the effectiveness of DMAIC in structured problem-solving. The study contributes to the growing literature on quality improvement in developing manufacturing sectors by showcasing the utility of Six Sigma in resource-limited environments. While improvement actions were not implemented in this phase, the study provides a foundation for real-time application and further innovation, particularly in integrating digital monitoring systems to enhance long-term process control.