Production process analysis using six sigma approach and failure mode effect analysis to reduce sheet break on core board paper products PT. Indonesian Papertech, Subang

Quality and productivity are the things that are most often the focus of discussion in the production process. PT. Papertech Indonesia is one of the companies producing cardboard products or paper board industry (hard paper). The products produced in addition to core paper also produce other types of paper including: Chip Board, Super Chip Board, Cone Board, Core B. In producing paper, the thing that most affects the quality of a product is the change grade or the change in the type of product. If at the time of change grade there is an error in the settings it will cause problems, namely sheet break or broken paper. Sheet Break is broken paper which can cause a decrease in machine productivity and add defective products in the warehouse, this defect product is meant to not meet the specifications of the consumer. Six Sigma approaches and Failure Mode Effect Analysis (FMEA) used in this study to determine the sigma level value for sheet breaks, factors that cause sheet breaks and find solutions to reduce risk. The results showed that there are two machines that often experience Sheet Break, namely Couch Roll & Lumbreaker and Dryer 1st Group machines which are caused by various factors. Based on the value of the Risk Priority Number which is the largest for the cause of Sheet Break, namely unstable vacuum during Change Grade, Lack of understanding and skills in the Change Grade state, Lack of understanding of the steps for Change Grade. Based on these results, recommendations are given to minimize the causes of priority Sheet Breaks carried out for each category and each cause, one of the recommendations given is the use of appropriate vacuum equipment, conducting regular monitoring, training employees and implementing Kaizen. With these recommendations, PT. Indonesian papertech can use these recommendations as a form of improvement in order to minimize the occurrence of sheet breaks.