Implementation of lean six sigma reducing E-DOWNTIME waste proposed improvement of flooring board production at PT. LBB Available to Purchase

Exports are crucial to support the country’s economy during pandemic. The important requirements for export competition are the conformity of the product with the standards of the destination country and improving the quality of the product. PT. LBB as an industry that produces and export flooring boards has quality problems where there is a lot of waste that will be solved using lean six sigma method. There are nine wastes identified at PT. LBB called E-DOWNTIME waste. The nine wastes have a sigma value range of 2.74-4.83 sigma and there are interrelated wastes. The selection was made using a priority matrix and resulted the most critical waste was defect. Each type of defect at PT. LBB analyzed by fishbone diagram followed by FMEA. The results were down grade and rejected defects had the highest RPN values, 426.67 and 320 points because there were knots or bores, chipped, and holes that pass quality control due to negligence of quality control officers. However, wood detection equipment is very expensive with a range of hundreds to billions of rupiah. For this reason, a proposal for improvement using poka yoke method is given by making a simple defect detection device using arduino nano to detect knots, bores, and chips on the wood surface before entering the next advanced production process. After testing, it was found that this simple tool was able to correctly detect 75% of sample. The tool, which costs only IDR. 300.000, can be further developed and can be integrated with manual sorting by quality control officers to improve defect prevention.